Bioconvection plays an inevitable role in introducing sustainable and environment-friendly fuel cell technologies. Bio-mathematical modelling of such designs needs continuous refinements to achieve strong agreements in experimental and computational results. Actually, microorganisms transport a miscellaneous palette of ingredients in manufacturing industrial goods particularly in fertilizer industries. Heat transfer characteristics of molecular structure are measured by a physical phenomenon which is allied with the transpiration of heat within matter. Motivated by bio-inspired fuel cells involved in near-surface flow phenomena, in the present article, we examine the transverse swimming of motile gyrotactic microorganisms numerically in a rheological Jeffery fluid near a stretching wall. The leading physical model is converted in a nonlinear system of ODEs through proper similarity alterations. A numerical technique called shooting method with R-K Fehlberg is applied via mathematical software and graphical presentations are obtained. The influence of all relative physical constraints on velocity, temperature, concentration, and volume fraction of gyrotactic microorganisms is expressed geometrically. It is found that heat and mass flux at the surface as well as density of motile microorganism’s declines for Brownian motion and thermophoresis parameter. Comparison in tabular form is made with existing literature to validate the results for limiting cases with convective boundary conditions.
Heat transfer mechanisms and their thermal performances need to be comprehensively studied in order to optimize efficiency and minimize energy losses. Different nanoparticles in the base fluid are investigated to upgrade the thermal performance of heat exchangers. In this numerical study, a finned shell and tube heat exchanger has been designed and different volume concentrations of nanofluid were tested to determine the effect of utilizing nanofluid on heat transfer. Fe2O3/water nanofluids with volume concentration of 1%, 1.5% and 2% were utilized as heat transfer fluid in the heat exchanger and the obtained results were compared with pure water. ANSYS Fluent software as a CFD method was employed in order to simulate the mentioned problem. Numerical simulation results indicated the successful utilization of nanofluid in the heat exchanger. Also, increasing the ratio of Fe2O3 nanoparticles caused more increment in thermal energy without important pressure drop. Moreover, it was revealed that the highest heat transfer rate enhancement of 19.1% can be obtained by using nanofluid Fe2O3/water with volume fraction of 2%.
This investigation numerically examined the combined impacts of different turbulator shapes, Al2O3/water nanofluid, and inclined magnetic field on the thermal behavior of micro-scale inclined forward-facing step (MSIFFS). The length and height for all turbulators were considered 0.0979 and 0.5 mm, respectively, and the Reynolds number varied from 5000 to 10000. In order to compare the skin friction coefficient (SFC) and the heat transfer rate (HTR) simultaneously, the thermal performance factor parameter (TPF) was selected. The results show that all considered cases equipped with turbulators were thermodynamically more advantageous over the simple MSIFFS. Besides, using Al2O3/water nanofluid with different nanoparticles volume fractions (NVF) in the presence of inclined magnetic field (IMF) increased HTR. With an increment of NVF from 1% to 4% and magnetic field density (MFD) from 0.002 to 0.008 T, HTR and subsequently TPF improved. The best result was observed for MSIFFS equipped with a trapezoidal-shaped turbulator with 4% Al2O3 in the presence of IMF (B=0.008 T). The TPF increased with the augmentation of Re, and the maximum value of it was 5.2366 for MSIFFS equipped with a trapezoidal-shaped turbulator with 4% Al2O3, B=0.008 T, and Re=10000.
This paper presents the analysis of two-layer cilia induced flow of Phan-Thien-Tanner (PTT) fluid with thermal and concentration effect. The Phan-Thien-Tanner fluid model has been used in the analogy of mucus present in the respiratory tract. The two-layer model approach was used due to the Peri Ciliary liquid Layer (PCL) and Airway Ciliary Layer (ACL) present on the epithelium cell in respiratory tract. The mathematical modelling of two-layer flow problem was simplified using long wavelength and small Reynold’s number approximation. The resulting differential equation with moving boundary gives exact solution for velocity, temperature and concentration profiles in two layers. The change in pressure has calculated by the results of velocity profile, also the pressure rise was evaluated by the numerical integration of pressure gradient along the channel wall. The impact of physical parameters on pressure rise, velocity, temperature and concentration profile was explained by the graphs. It can be seen from graphs that velocity and temperature profile are maximum in the inner layer of fluid (PCL) and concentration profile is maximum at outer layers of fluid (ACL).
A numerical analysis of the log-law behavior for the turbulent boundary layer of a wall-bounded flow is performed over a flat plate immersed in three nanofluids (ZnO-water, SiO2-water, TiO2-water). Numerical simulations using CFD code are employed to investigate the boundary layer and the hydrodynamic flow. To validate the current numerical model, measurement points from published works were used, and the compared results were in good compliance. Simulations were carried out for the velocity series of 0.04, 0.4 and 4 m/s and nanoparticle concentrations 0.1% and 5%. The influence of nanoparticles’ concentration on velocity, temperature profiles, wall shear stress, and turbulent intensity was investigated. The obtained results showed that the viscous sub-layer, the buffer layer, and the log-law layer along the potential-flow layer could be analyzed based on their curving quality in the regions which have just a single wall distance. It was seen that the viscous sub-layer is the biggest area in comparison with other areas. Alternatively, the section where the temperature changes considerably correspond to the thermal boundary layer’s thickness goes a downward trend when the velocity decreases. The thermal boundary layer gets deep away from the leading edge. However, a rise in the volume fraction of nanoparticles indicated a minor impact on the shear stress developed in the wall. In all cases, the thickness of the boundary layer undergoes a downward trend as the velocity increases, whereas increasing the nanoparticle concentrations would enhance the thickness. More precisely, the log layer is closed with log law, and it is minimal between Y+=50 and Y+=95. The temperature for nanoparticle concentration φ=5% is higher than that for φ=0.1%, in boundary layers, for all studied nanofluids. However, it is established that the behavior is inverted from the value of Y+=1 and the temperature for φ =0.1% is more important than the case of φ =5%. For turbulence intensity peak, this peak exists at Y+=100 for v=4 m/s, Y+=10 for v=0.4 m/s and Y+=8 for v=0.04 m/s.
The backward-facing step is a critical problem existing in many engineering and industrial applications. In this study, a semi-porous baffle (the root of the baffle is a porous medium and the tip is solid) is placed behind the step. The effects of the length of the porous part, and the baffle location on the energy transfer and pressure drop are studied in different Reynolds numbers (Re=100, 200, 300, 400, 500). The effect of the Darcy number of the porous medium on the aforementioned parameters is also investigated. Both the local maximum and average relative Nusselt numbers (divided by the Nusselt of the base case with no baffle at the same Reynolds) and relative pressure drop (calculated as the relative Nusselt number) are reported. The results show that by adoption of the proper length of the porous medium, the average relative and maximum local Nusselt numbers could be enhanced by 20% and 90%, respectively. Low permeable porous media give better energy transfer. For example, porous media with Da=10−5 give 30% better maximum local Nusselt number and about 7% higher average Nusselt number with respect to the same case with Da=10−2.
This exploration examines unsteady magnetohydrodynamic (MHD) three-dimensional flow of viscous material between rotating plates subject to radiation, Joule heating and chemical reaction. The non-linear partial differential system is re-structured into the ordinary differential expressions by the implication of appropriate transformations. The developed differential equations are computed by homotopy analysis technique. Numerical consequences have been accomplished by various values of emerging parameters. Coefficients of skin friction and heat and mass transfer rates have been scrutinized. Irreversibility analysis is carried out. Influence of various prominent variables on entropy generation is presented. Moreover, the temperature increases for higher Dufour number and concentration distribution reduces against Soret number. Higher squeezing parameter enhances velocity while concentration reduces with an increment in squeezing parameter. Both entropy rate and Bejan number increase against higher diffusion parameter.
In this study, the stagnation point transport of second grade fluid with linear stretching under the effects of variable thermal conductivity is considered. Induced magnetic field impact is also incorporated. The nonlinear set of particle differential equations is converted into set of ordinary differential equations through appropriate transformation. The resulting equations are then resolved by optimal homotopy analysis method. The effect of pertinent parameters of interest on skin friction coefficient, temperature, induced magnetic field, velocity and local Nusselt number is inspected by generating appropriate plots. For numerical results, the built-in bvp4c technique in computational software MATLAB is used for the convergence and residual errors of obtained series solution. It is perceived that the induced magnetic field is intensified by increasing β. It can also be observed that skin friction coefficient enhances with increasing value of magnetic parameter depending on the stretching ratio a/c. For the validness of the obtained results, a comparison has been made and an excellent agreement of current study with existing literature is found.
In this article, the effect of using water/zinc oxide nanofluid as a working fluid on the performance of solar collector is investigated experimentally. The volumetric concentration of nanoparticles is 0.4%, and the particle size is 40 nm, and the mass flow rate of the fluid varies from 1 to 3 kg/min. For this experiment, a device has been prepared with appropriate measuring instruments whose energy source is solar radiation. The solar energy absorbed by the flat plate collector is absorbed by the nanofluid of water/zinc oxide. The nanofluid is pumped to the consumer, a heat exchanger, where it heats the water. The temperature, radiation level, flow rate, and pressure in different parts of the device were measured. The pressure drop and the heat transferred are the most important results of this experimental work. The ASHRAE standard is used to calculate efficiency. The results showed that the use of water/zinc oxide nanofluid increases the collector performance compared to water. For 1 kg/min of mass flow rate, the nanofluids have a 16% increase in efficiency compared to water. From the results, it can be concluded that the choice of optimum mass flow rate in both water and nanofluid cases increases efficiency.
In the present study, hydraulic and thermal behavior of an automatic transmission nano-fluid (ATNF) inside a tube with a twisted tape has been investigated. The heat transfer improvement and pressure drop of transmission oil for each of case of using twisted tape and nano-particles were also examined separately and compared with each other. The CuO nano-particles were used to prepare the ATNF. The effects of different Reynolds numbers and different mass fractions of nano-particle were investigated. The results showed that applying nano-particles and twisted tape simultaneously increases both the pressure drop and Nusselt number, on average by about 53% and 76%, respectively. By using a parameter, namely thermal performance index η, the effect of increasing heat transfer and pressure drop was studied simultaneously. The heat transfer improvement predominates the pressure drop increment in all cases. It was observed that the highest thermal performance of 1.9 was obtained at Re=634 and ϕ =2%. Furthermore, regarding the increment of the Nu number, it was shown that the use of twisted tapes individually could increase the average Nu number by 41%, while the max increment arising from individual use of 2% nano-particles is 13%, so using twisted tape is a more effective-technique for this case study.
In this study, the effect of influencing parameters on the stress distribution around a polygonal cutout within a laminated composite under uniform heat flux was analytically examined. The analytical method was developed based on the classical laminated plate theory and two-dimensional thermo-elastic method. A mapping function was employed to extend the solution of a perforated symmetric laminate with a circular cutout to the solution of polygonal cutouts. The effect of significant parameters such as the cutout angular position, bluntness and aspect ratio, the heat flux angle and the laminate stacking sequence in symmetric composite laminate containing triangular, square and pentagonal cutouts was studied. The Neumann boundary condition was used at the edges of the thermally insulated polygonal cutout. The laminate was made of graphite/epoxy (AS/3501) material with two different stacking sequences of [30/45]s and [30/0/−30]s. The analytical solutions were well validated against finite element results.
This work represents a 3D numerical study of the effects of carbon nanotube (CNT)-water nanofluids on the double diffusive convection inside the triangular pyramid solar still. This numerical investigation is performed for wide ranges of governing parameters such as buoyancy ratio (−10⩽N⩽0), volumetric fraction of nanoparticles (0⩽φ⩽0.05) and Rayleigh number (103⩽Ra⩽105). The results are presented in terms of flow structure, temperature field, heat and mass transfer rates variations. It was found that the buoyancy ratio can be considered as an optimizing parameter for the heat and mass transfer, and the use of CNT has a positive effect on the solar still performances.
Increasing the temperature of photovoltaic systems reduces electrical efficiency, output power, as well as results in permanent damages in the long-term run. A new hybrid PV/PCM-Rib system with three different rib pitch ratios of Λ =4, Λ =2 and Λ =1 is investigated to reduce PV temperature and achieve uniform temperature distribution. A comprehensive two-dimensional model of the systems is developed and simulated with a fixed inclination angle of 30°. A parametric study is carried out to investigate the impact of ribs on different melting temperatures (50, 40 and 30 ° C). According to the numerical results and the parametric analysis, using ribs shows better performance in temperature reduction for PCM with a lower melting temperature. By lowering the melting temperature of PCM from 50 to 30 °C, the average temperature reduction of PV/PCM-Rib in the case of Λ =1 increases from 1.39% to 5.16% while the average melted PCM decreases from 20.5% to 7.59% after 240 min. It means that using ribs provides more solid PCM. It is also obtained that the electrical efficiency and output power show more increments at lower melting temperatures.
In this paper, the performance of a solar thermal system with a focus on space heating was investigated. A 70 m2 detached house was considered in the weather conditions of the city of Tehran, Iran. A thermosyphon solar water heater with a flat plate collector combined with an auxiliary electrical heater supplies the heating demand of the house. The proposed system was modeled and analyzed using TRNSYS software. In this regard, the TRNBuild module was employed for the building load calculation. The model has been simulated for one year of operation. The effects of the solar collector’s surface area and storage volume were assessed. The results show that for a solar collector with a 15 m2 surface area, the solar fraction is 0.29 in January, during which the solar radiation is the lowest. Using solar collectors of 10 m2 and 5 m2 surface areas, the solar fraction falls to 0.23 and 0.14, respectively in January. Besides, two cases of 150 L and 300 L storage tanks are taken into account. Eventually, it is found that using a 15 m2 solar collector and a 150 L storage tank can appropriately provide the building’s heating demand taking the thermal performance and economic aspects into consideration.
Heat transfer enhancement in vertical tubes plays an important role on the thermal performance of many heat exchangers and thermal devices. In this work, laminar mixed convection of airflow in a vertical dimpled tube was numerically investigated. Three-dimensional elliptical governing equations were solved using the finite-volume technique. For a given dimpled pitch, the effects of three different dimple heights (h/D=0.013, 0.027, 0.037) have been studied at different Richardson numbers (0.1, 1.0 and 1.5). The generated vortex in the vicinity of the dimple destructs the thermal boundary layer and enhances the heat transfer. Therefore, lower wall temperature is seen where the dimples are located. Fluid flow velocity at the near-wall region significantly increases because of buoyancy forces with the increase of Richardson numbers. Such an acceleration at the near-wall region makes the dimples more effective at higher Richardson number. Using a dimpled tube enhances the heat transfer coefficient. However, the pressure drop is not important. For instance, in the case of Ri=1.5 and h/D=0.037, 20% gains in the heat transfer enhancement only costs 2.5% in the pressure loss. In general, it is recommended using a dimpled tube where the effects of buoyancy forces are important.
In present work, a helical double tube heat exchanger is proposed in which an advanced turbulator with blades, semi-conical part, and two holes is inserted in inner section. Two geometrical parameters, including angle of tabulator’s blades (θ) and number of tabulator’s blades (N), are considered. Results indicated that firstly, the best thermal stratification is achieved at θ=180°. Furthermore, at the lowest studied mass flow rate (), heat transfer coefficient of turbulator with blade angle of 180° is 130.77%, 25%, and 36.36% higher than cases including without turbulator, with turbulator with blade angle of θ=240°, and θ =360°, respectively. Moreover, case with N=12 showed the highest overall performance. At the highest studied mass flow rate (), heat transfer coefficient for case with N=12 is up to 54.76%, 27.45%, and 6.56% higher than cases including without turbulator, with turbulator with N=6, and with turbulator with N=9, respectively.
Heat pipes are most frequently used for thermal management solutions. Selection of right type of heat pipe for a specific scenario is utmost necessary for best outcomes. The purpose of this research is comparison of thermal performance characteristics of sintered copper wicked and grooved heat pipes, which are mostly used types of heat pipes. Distilled water filled heat pipes were tested through experimentation in gravity assisted position. Experimental outcomes have been compiled in terms of capillary pressure, operating temperature, thermal resistance and heat transfer coefficient. Capillary pressure is high in sintered heat pipes compared to grooved heat pipes irrespective of groove dimensions. Grooved heat pipes have lower operating temperature compared to sintered heat pipes at the same heat load. At 8 W, compared to sintered heat pipes, grooved heat pipes have 8.24% lower condenser surface temperature, 4.41% lower evaporator surface temperature and 7.79% lower saturation temperature. Thermal resistance of sintered heat pipe is much lower than grooved heat pipe. The maximum relative difference of 63.8% was observed at 8 W. Heat transfer coefficient of sintered heat pipe was observed double compared to grooved heat pipe at 8 W heat load. Thermal resistance and hence heat transfer coefficient of sintered heat pipe change almost in a linear manner with respect to heat load but unexpectedly turning point is observed in thermal resistance and heat transfer coefficient of grooved heat pipe. Grooved heat pipes attain equilibrium much earlier compared to sintered ones. Varying heat loads from 4 to 20 W causes variation in equilibrium establishment time from 7 to 4 min for grooved and from 10 to 7 min for sintered heat pipes.
In the present work, effects of various heat transfer fluids on the discharging performance of a phase change material (PCM) included cylindrical container are numerically assessed during forced convection. The heat transfer fluid air, hydrogen, water and nanofluid with alumina particles are used and the the geometric variation of the PCM embedded region is also considered. The finite element method is used as the solver. Dynamic features of heat exchange with various phases are explored for different heat transfer fluid types, Reynolds number (between 100 and 300) and PCM embedded region geometric variation (hx between 0.01d1 and 0.65d1, hy between 0.1h1 and 0.4h1). It is observed that discharging time is significantly influenced by the heat transfer fluid type while full phase transition time for air is obtained as more than 10 times when hydrogen is utilized as heat transfer fluid. The best performance is achieved with nanofluid. When the PCM integrated region size is reduced, discharging time is generally reduced while due to the form of the geometry, vortex formation is established in the PCM region. This results in performance degeneration at the highest radius and height of the inner cylinder. Discharging time increases by about 12% when radius of the inner cylinder is increased from hx=0.35d1 to hx=0.45d1. Dynamic features of PCM temperature and liquid fraction are affected with Reynolds number while discharging time is reduced by about 48% when configurations with the lowest and highest Reynolds number are compared.
The aim of this study is to examine the effects of local curvature and elastic wall effects of an isothermal hot wall for the purpose of jet impingement cooling performance. Finite element method was used with ALE. Different important parametric effects such as Re number (between 100 and 700), Ha number (between 0 and 20), elasticity (between 104 and 109), curvature of the surface (elliptic, radius ratio between 1 and 0.25) and nanoparticle volume fraction (between 0 and 0.05) on the cooling performance were investigated numerically. The results showed that the average Nu number enhances for higher Hartmann number, higher values of elastic modulus of partly flexible wall and higher nanoparticle volume fraction. When the magnetic field is imposed at the highest strength, there is an increase of 3.85% in the average Nu for the curved elastic wall whereas it is 89.22% for the hot part above it, which is due to the vortex suppression effects. Nanoparticle inclusion in the base fluid improves the heat transfer rate by about 27.6% in the absence of magnetic field whereas it is 20.5% under the effects of magnetic field at Ha=20. Curvature effects become important for higher Re numbers and at Re=700, there is 14.11% variation in the average Nu between the cases with the lowest and highest radius ratio. The elastic wall effects on the heat transfer are reduced with the increased curvature of the bottom wall.
The main purpose of this research is the second-order modeling of flow and turbulent heat flux in non-premixed methane-air combustion. A turbulent stream of non-premixed combustion in a stoichiometric condition, is numerically analyzed through the Reynolds averaged Navier-Stokes (RANS) equations. For modeling radiation and combustion, the discrete ordinates (DO) and eddy dissipation concept model have been applied. The Reynolds stress transport model (RSM) also was used for turbulence modeling. For THF in the energy equation, the GGDH model and high order algebraic model of HOGGDH with simple eddy diffusivity model have been applied. Comparing the numerical results of the SED model (with the turbulent Prandtl 0.85) and the second-order heat flux models with available experimental data follows that applying the second-order models significantly led to the modification of predicting temperature distribution and species mass fraction distribution in the combustion chamber. Calculation of turbulent Prandtl number in the combustion chamber shows that the assumption of Prt of 0.85 is far from reality and Prt in different areas varies from 0.4 to 1.2.
In the field of heat pumps, there are a number of parameters that affect the performance and efficiency of the apparatus, which have been the subject of studies by individual researchers in the literature. This study describes an experimental method in order to investigate the effects of some significant parameters on heat pump performance. In this regard, a laboratory heat pump setup has been utilized to operate in different working conditions for achieving an appropriate estimation to find out effects of mentioned parameters such as refrigerant type and charge amount, compressor oil viscosity, compressor cooling fan, secondary fluids temperature and flow rate. Different refrigerants have been selected and used as circulating fluid in the installed heat pump. Although this work has been devoted to a detailed attempt to recognize the effects of various parameters on the coefficient of performance (COP) value, an appropriate method has been carried out to survey the obtained results by using economic analysis. It was revealed that one of the main parameters is refrigerant charge amount which has a notable effect on COP. The temperature of the heat source was also tested and the performance of the system increased by more than 11% by employing mentioned modifications and various operating conditions. In addition, by selecting a low viscosity compressor oil, the system performance increased by 18%. This improvement is more than 6% for the case that cooling fan is installed to cool the compressor element.
A numerical investigation was carried out on the effect of carbon nanotube (CNT)-water-nanofluid-filled Trombe wall on heat transfer and fluid flow inside a 3D typical room. Time depending governing equations are considered with applying hot temperature at the left surface (collector) of the Trombe wall. The left wall (glazing) of the room and a square part (window) at the right wall are considered at cold temperature. The effects of Rayleigh number and the nanofluid volume fractions and the Trombe wall height on the temperature field, flow structure and heat transfer rate, are studied. The results show that the addition of nanoparticles and the increase of the Trombe wall height, enhance the heat transfer considerably and affect the flow structure and the temperature field.
In this research, the thermal performance of a single U-tube vertical ground heat exchanger is evaluated numerically as a function of the most influential flow parameters, namely, the soil porosity, volumetric heat capacity, and thermal conductivity of the backfill material, inlet volume flow rate, and inlet fluid temperature. The results are discussed in terms of the variations of the heat exchange rate, the effective thermal resistance, and the effectiveness of the ground heat exchanger. They show that the inlet volume flow rate, inlet fluid temperature, and backfill material thermal conductivity have significant effects on the thermal performance of the ground heat exchanger, such that by decreasing the inlet volume flow rate and increasing the backfill material thermal conductivity and inlet fluid temperature, the outlet fluid temperature decreases considerably. On the contrary, the soil porosity and backfill material volumetric heat capacity have negligible effects on the studied ground heat exchanger’s thermal performance. The lowest inlet fluid temperature reaches a the maximum effective thermal resistance of borehole and soil, and consequently the minimum heat transfer rate and effectiveness. Also, multilinear regression analyses are performed to determine the most feasible models able to predict the thermal properties of the single U-tube ground heat exchanger.
In this study, based on the established heat transfer and mechanical stress models, thermal stress distribution of glazing unit filled with paraffin was studied for various temperature differences between indoor and outdoor conditions. The strain produced on the surface of glazing unit filled with paraffin varies greatly in the outdoor temperature range of − 30 °C–40 °C. Furthermore, phase change material (PCM) layer between the glass panes significantly affects the strain values at different temperatures, which can respectively reach up to about 250×10−6 and down to −300×10−6 for tensile and compressive strains once the paraffin is in liquid state. Additionally, impacts of boundary conditions on the strain values are more pronounced within the distance of 0.01 m from the edges of the glazing window. The presented model and outcomes can be used as a guide to simulate thermal stress in glazing units filled with paraffin.
In the present study, the insulation mechanism of building walls during the summer days and nights is investigated with a realistic approach to enhance their performance. A fiber layer, as a porous medium with air gaps, is used along the wall layers to decrease the energy loss. Meanwhile, the radiation heat flux variation during five days in a row has been considered for each side of the building, and it is tried to reach the optimum values for geometrical factors and find suitable insulation for each side of the building. A lattice Boltzmann method (LBM) based code is developed to simulate the actual chain of the heat transfer which consists of radiation, conduction, forced and natural convection combination within wall layers including fiber porous insulation. The results indicate that for the current insulation model, the effect of natural convection on the heat transfer is not negligible and the existence of the porous layer has caused a positive impact on the heat loss reduction by decreasing the circulation speed. Also, by using the optimum location and thickness for the insulation layer, it is showed that each side of the building has different rates of energy loss during a day, and for the appropriate insulation, they need to be evaluated separately.
Commercial pure aluminum and galvanized carbon steel were lap-welded using the weld-brazing (WB) technique. Three types of aluminum filler materials (4043, 4047, and 5356) were used for WB. The joint strength and intermetallic compounds at the interface of three series of samples were analyzed and compared. Depending on the Si content, a variety of ternary Al-Fe-Si intermetallic compounds (IMCs) such as Fe4(Al, Si)13, Fe2Al8Si(τ5), and Fe2Al9Si2 (τ6) were formed at the interface. Mg element in 5356 filler material cannot contribute to the formation of Al-Fe intermetallic phases due to the positive mixing enthalpy of Mg-Fe. The presence of Mg enhances the hot cracking phenomenon near the Al-Fe intermetallic compound at the interface. Zn coating does not participate in intermetallic formation due to its evaporation during WB. It was concluded that the softening of the base metal in the heat-affected zone rather than the IMCs determines the joint efficiency.