Deep convolutional encoder-decoder hierarchical neural networks for conjugate heat transfer surrogate modeling

Conjugate heat transfer (CHT) models are vital for the design of many engineering systems. However, high-fidelity CHT models are computationally intensive, which limits their use in applications such as design optimization, where hundreds to thousands of model evaluations are required. In this work, we develop a modular deep convolutional encoder-decoder hierarchical (DeepEDH) neural network, a novel deep-learning-based surrogate modeling methodology for computationally intensive CHT models. Leveraging convective temperature dependencies, we propose a two-stage temperature prediction architecture that couples velocity and temperature models. The proposed DeepEDH methodology is demonstrated by modeling the pressure, velocity, and temperature fields for a liquid-cooled cold-plate-based battery thermal management system with variable channel geometry. A computational model of the cold plate is developed and solved using the finite element method (FEM), generating a dataset of 1,500 simulations. The FEM results are transformed and scaled from unstructured to structured, image-like meshes to create training and test datasets. The DeepEDH methodology's performance is examined in relation to data scaling, training dataset size, and network depth. Our performance analysis covers the impact of the novel architecture, separate field models, output geometry masks, multi-stage temperature models, and optimizations of the hyperparameters and architecture. Furthermore, we quantify the influence of the CHT thermal boundary condition on surrogate model performance, highlighting improved temperature model performance with higher heat fluxes. Compared to other deep learning neural network surrogate models, such as U-Net and DenseED, the proposed DeepEDH methodology for CHT models exhibits up to a 65% enhancement in the coefficient of determination ($R^{2}$).