Multiphysics Analysis of Weld Defects and Thermal Contact Resistance in H-Fin Tube

Articles in Press

Document Type : Full Length Research Article

Authors

1 Department of Mechanical Engineering, All India Shri Shivaji Memorial Society's College of Engineering, 1, Kennedy Road, Pune. 411 001.

2 Department of Technology, Savitribai Phule Pune University

Abstract

This study investigates the thermal–hydraulic performance of a single H-type fin-and-tube heat exchanger, emphasizing the influence of weld quality and thermal contact resistance at the fin–tube interface. The research addresses a critical gap regarding how imperfect welds and interfacial resistance affect the efficiency of H-type fin–tube heat exchangers commonly used in waste heat recovery applications. The methodology combines physical modeling to conceptualize geometry and thermal–fluid interactions, mathematical formulation to define governing equations for conjugate heat transfer and turbulent flow, and numerical simulations using ANSYS FLUENT to evaluate steady-state performance. Results show that a thin resistive layer with a thermal contact resistance of 3.08 × 10⁻⁶ K•m²/W reduces the overall heat transfer coefficient, Nusselt number, and Colburn j-factor by approximately 8%, while the friction factor remains largely unaffected. Velocity and temperature profiles reveal localized flow acceleration and temperature gradients near imperfect welds, highlighting regions prone to thermal hotspots. Discontinuous welds with incomplete penetration (GL/Ft = 0, Gw = 0.01 mm) immediately reduce heat transfer efficiency by 13%, escalating to ~50% over long-term operation due to localized overheating, corrosion, and fatigue. The novelty of this work lies in its Multiphysics framework, which quantifies hidden effects of weld discontinuities and provides practical insights for heat exchanger design optimization, weld quality assurance, and long-term reliability of compact energy recovery systems.

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Main Subjects

Journal of Heat and Mass Transfer Research

Articles in Press, Accepted Manuscript
Available Online from 29 November 2025

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History

  • Receive Date: 01 September 2025
  • Revise Date: 01 November 2025
  • Accept Date: 29 November 2025

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