Date of Award
Spring 2026
Embargo Period
1-1-2036
Access Type
Dissertation - ERAU Login Required
Degree Name
Doctor of Philosophy in Mechanical Engineering
Department
Mechanical Engineering
Committee Chair
Sandra K.S. Boetcher
Committee Chair Email
boetches@erau.edu
Committee Advisor
Sandra K.S. Boetcher
Committee Advisor Email
boetches@erau.edu
First Committee Member
Rafael Rodriguez
First Committee Member Email
rodri7d6@erau.edu
Second Committee Member
Eduardo Divo
Second Committee Member Email
divoe@erau.edu
Third Committee Member
Mark Ricklick
Third Committee Member Email
ridlickm@erau.edu
Fourth Committee Member
R.R. Mankbadi
Fourth Committee Member Email
mankbadr@erau.edu
College Dean
James W. Gregory
Abstract
Thermal energy storage systems play an important role in improving energy efficiency, enabling load shifting, and supporting the integration of renewable energy technologies. Latent heat thermal energy storage using phase change material (PCM) offers high energy storage density and near isothermal operation, making it particularly attractive for ambient and cold temperature applications. Despite these advantages, widespread adoption of PCMs remains limited due to challenges related to low thermal conductivity, material stability, containment, and system level integration. Additive manufacturing presents new opportunities to address these limitations through advanced geometries and multifunctional thermal energy storage designs.
This dissertation investigates the characterization and integration of PCMs for additively manufactured thermal energy storage systems operating in the temperature range of -30 to 35◦C. A comprehensive review of organic, inorganic, eutectic, and commercial PCMs is first presented, with emphasis on thermophysical properties, phase change behavior, stability, and material compatibility relevant to cold storage and cooling applications. Key design considerations for selecting PCMs and configuring thermal energy storage systems are identified and synthesized into a unified framework.
To address the inherently low thermal conductivity of PCMs, analytical and numerical investigations are conducted to examine the influence of geometry, heat transfer coefficients, and characteristic length scales on melting behavior. These findings are then extended through experimental characterization of PCM and high density polyethylene functional composites, including mechanical properties, thermal conductivity, phase change temperatures, and latent heat of fusion. The results demonstrate the tradeoffs between structural integrity and thermal performance when incorporating PCMs into polymer based matrices.
The dissertation further evaluates the performance of additively manufactured triply periodic minimal surface (TPMS) heat exchangers integrated with PCM thermal storage. Numerical simulations are performed to characterize melting behavior, heat transfer rates, pressure drop, and overall system performance for gyroid, diamond, splitP, and lidinoid geometries under varying inlet temperatures and flow rates. The results show that TPMS geometries significantly enhance heat transfer and reduce melt times compared to conventional designs, with geometry driven effects dominating system performance while maintaining relatively low pressure losses.
Overall, this work provides a comprehensive assessment of PCM selection, characterization, and integration within additively manufactured thermal energy storage systems. The findings offer practical design guidance and demonstrate the potential of advanced geometries to overcome key limitations of PCMs, supporting their broader adoption in thermal management and energy storage applications.
Scholarly Commons Citation
Messenger, Melissa, "Phase-Change Material Characterization for Additively Manufactured Thermal Energy Storage Systems" (2026). Doctoral Dissertations and Master's Theses. 957.
https://commons.erau.edu/edt/957
