Fin-and-Tube Heat Exchanger Design & Thermal Analysis

Parametrically modeled a high-efficiency fin-and-tube heat exchanger core designed for compact thermal management applications. Modeled copper tube passes with optimized staggered arrangements and aluminum plate fins to maximize surface area density and boundary layer disruption. Evaluated air-side and tube-side conjugate heat transfer using flow simulation, identifying core pressure drops and local recirculation dead-zones. Prepared complete manufacturing documentation, including sheet metal casing flat patterns, brazed tube assembly specifications, and fabrication drawings.