Topology optimization of liquid-cooled heat exchangers for data centers: Methods, tools and evaluation

Abstract

With the continuous rise in energy consumption within data centers, optimizing liquid-cooled heat exchangers has become crucial for effective thermal management. Topology optimization has emerged as a groundbreaking design method that transcends the limitations of traditional design performances. This review systematically examines recent advancements in the topology optimization of liquid-cooled heat exchangers, focusing on key methodological aspects, including design parameterization methods, numerical simulation tools, and optimization algorithms. Through comparative analysis, current research trends and key gaps are identified. Density-based methods remain dominant due to their high computational efficiency. However, these methods still suffer from blurred boundaries. These methods also rely heavily on post-processing techniques. In contrast, explicit methods can generate clear geometric boundaries. However, they still face many significant challenges. Furthermore, a persistent problem has been identified in the research. Most studies are still limited to single-objective, two-dimensional, and steady-state simulations. Whether these designs can be manufactured and fulfill their intended performance requirements is another concern. Experimental validation for these designs is limited. This has led to significant challenges in translating research findings into manufacturable, high-performance designs applicable to real-world data centers. However, recent years have brought new perspectives, driven by upgrades in computer hardware, enhanced computational capabilities, and the integration of new technologies. This review provides a structured framework to help bridge the gap between research and application, with the ultimate goal of guiding the field toward more efficient, compact, and sustainable heat exchanger solutions.