Mother of all Cascades, -100ºc Dual Evap that Cools the Motherboard also!!

[extremecorvette]

Mother of all Cascades, -100ºc Dual Evap that Cools the Motherboard also!!

I'm a student at Iowa State University, I have two degrees, on in Mechanical Engineering and another in Industrial. I went to my professors with a idea of a dual evaporator cascade system that will cool both the CPU and GPU down to -100ºc. I had no experience with phase cooling before I started this project. After looking into what all was needed and all the insulating I would need to do I quickly decided I needed to find a better way to protect the boards against condensation. I had come up with a idea of a sealed case filed with dry nitrogen. I didn't like the idea if my seal breaks everything would fry in minutes after the pressure dropped in the case. I looked at building a controller that would cut the power to every thing if the pressure dropped below a set point. During a meeting with some professors the idea got brought up about using a dielectric. So when I looked into it 3M had a few that would take the temps I wanted to reach. So I switched from dry nitrogen to 3M HFE-7500 dielectric. I worked with Reggie Wing at xtremesystems.org, he has been the number one person that has helped me come up with the design for the cascade system and evaporator blocks.

I have worked with all these people on this project, they have all been a huge help. I will go in to more details when I do the write up for the article.

Reggie Wing at http://xtremesystems.org
Phil E. Tuma at 3M http://mmm.com/
Patti Mikula at ATI http://ati.com/
Jon Carvill at ATI http://ati.com/
Jennifer Barron at ATI http://ati.com/
David Taue at Antec http://www.antec.com/InternationalWelcome.php
Carol S. Archer at Western Digital http://wdc.com/en/index.asp?Language=en
Jake Ward at Centon Memory http://www.centon.com/
Randy Torio at Centon Memory http://www.centon.com/
Alex Mei at OCZTechnology http://ocz.com/
Darin Stoll at Mechanical Comfort Inc
Adam Lintott at Matrix Orbital http://matrixorbital.com/
Fred Namei at Danfoss http://danfoss.com/
Brian Flynn at Ritchie Engineering http://ritchieengineering.com/
Dave Berry at WTT America http://wttamerica.com/
James Nelson at Refrigeration Research http://refresearch.com/
Edward Kerins, Jr. at Cambridge-Lee Industries http://www.camlee.com/
Gene Ziegler at Sporlan/Parker http://sporlan.com/
Julian Parker at Henry Technology http://henrytech.com/
David Metcalf at Honeywell International http://honeywell.com/
Benjamin Benulis at AMD http://www.amd.com/us-en/
Jim Bogart at http://flatplate.com/
JoAnn Buonomo at http://www.monmouthrubber.com/
Danner Mfg. at http://dannermfg.com/

Builders of the Controller are Mariano Porta AKA Ssilencer & Hernan Martinez Reina AKA Golden Eagle Mail: msporta@2vias.com.ar

The goal is to hit -100ºc and cool the 3M HFE-7500 dielectric to -40 ºc to -20 ºc









Chilly1 Block


Chilly1 Block done on CNC

[extremecorvette]

I put passed dry nitrogen thought the block, it helps keep the from oxidizing the black all over the outside of the block.







Pressure tested up to 300 psi

[extremecorvette]

Once the blocks are pressure checked for leaks, I was able to start polishing the bottom of the evaporator blocks. The purpose of polishing the block is to make sure I have a flat surface and to maximize the surface contact with the CPU. I started out with 300 grit moving up to 400, 600, 800, 1000, 1200, 1500, and finally 2000 grit.



This is the picture after wet sanding with 2000 grit paper. You check to make sure you have sanding lines all the way across the bottom of the block.



After sanding with 2000 grit I moved up to 0.3-micron polishing wheel. The polishing wheel uses a cloth surface with a 0.3-micron aluminum polish suspended in water.



Once I used the 0.3-micron polishing wheel with 0.3-micron aluminum polish, I move down to 0.05-micron polishing wheel with 0.05-micron aluminum polish. You can see the difference polishing makes in the surface. 2000 grit vs. 0.05-micron aluminum polish.



Once both blocks are done, I moved down to 0.005-micron vibrating polish bath.




Once done you can see the difference from 0.05-micron vs. 0.005-micron but not too well with the camera.

[extremecorvette]

The 17� x 96� piece of aluminum on the plasma bed getting ready to cut. 7-21-05





Bending it into the case







TIG welding tabs for the CD Rom and hard drives

[n00b 0f l337]

Looking good so far, but there are a lot of cascades that can do that.

[extremecorvette]

I have to insulate the case that the motherboard and dielectric will be in.





I put 2" of closed cell foam



Gauges donated by Chilly1

[Noldor]

Good God!

[Activate: AMD]

dude, dont bring the man down


looks like AMAZING work!

the case is HUGE!

[extremecorvette]

I will keep posting new pictures as the project goes on. I will also be posting the OCing part when I get the project done.

Link to all the Pictures

[afireinside]

Thats THE most insane thing I've seen along with 5 liquid chilled TECs on an AXP I think its pretty pointless to go through so much trouble when you could just use lots of foam and spray the board but if you want to go all out then more power to ya! Good luck!

[k|ngp|n]

Incredible work man...
I can't wait to see the thing finished.

[sandman]

That sir, is a work of art.

I'm speechless. Just god, I want that.

Fantastic job thusfar.

[Lando95]

Looking good so far, but there are a lot of cascades that can do that.

Umm, no there are not, not that can hold dual evaps at -100C plus cool the mobo.



That is soooo sweet Corvette!!!! That is one hell of a machine shop!!! Is that at the university?

[Spanners]

Super job man , love it will be checking back often
edit:

I think its pretty pointless to go through so much trouble when you could just use lots of foam and spray the board but if you want to go all out then more power to ya! Good luck!

Maybe but -40 ºc to -20 ºc on the motherboard has to have some results .

Looking good so far, but there are a lot of cascades that can do that.

Yeah three of them blocked my car in this mourning and one mugged my mother they're everywhere

[runmc]

If you can pull this off I will be simply amazed

[zabomb4163]

edit:
Maybe but -40 ºc to -20 ºc on the motherboard has to have some results .

yeah, caps get too cold and dont function properly anymore....

[afireinside]

At -40C I'd be afraid the caps would start freaking out... I think it would be a better idea to build the cascade and then build a very small AC unit with the evap build above the mobo and have a powerful fan blowing 0C air over the entire motherboard.

[GuGaCoSa]

Holy Sh*t,i got very impressed at all the buiding,the box,the project itself,the idea for cooling motherboard and all,will be refreshing this page every 5 minutes to see if something new appeared hehe,btw chilly doing a great job suplying parts for that kind of projects
---EDIT---
Will u use some kind of controller for this beast?If so,what will be?
Thank you

[n00b 0f l337]

Not the mobo cooling. Sorry for my comment. Didnt see that part. Hehe.. Awesome crap... I wanna see a WR on something.

[wdrzal]

Nice professional fabrication work!!!!

you may consider mounting a heat sheild above the compressors to keep the heat off the box and to channel air over the top of them.

[masterofpuppets]

The mobo cooling WILL NOT work. I've been over this with other people in the past, the capacitors just don't work at low temps.

[skirms_fr]

impressive

very nice work there

[Athens[2004]]

good work here/.

[Jack22]

The mobo cooling WILL NOT work. I've been over this with other people in the past, the capacitors just don't work at low temps.

That's important...


But awsome stuff man! It ooks great!!

[wdrzal]

in your drawing you missed listing "22" I beleive its a accumalator, That design should work nicely.