Abstract—This study presents a thorough characterization and validation of R410A condensation performance in split air conditioning units, offering actionable insights for industry and addressing the critical challenges of energy efficiency and climate adaptation in regions such as the Kurdistan Region of Iraq. By integrating advanced experimental instrumentation with high-fidelity Computational Fluid Dynamics (CFD) modeling, it presents a comprehensive investigation of two-phase flow dynamics across the full length of an 8.914 m copper condenser tube. Forty-one precisely calibrated temperature sensors and pressure transducers provide real monitoring of thermal and flow behavior. The Volume of Fluid (VOF) method with geometric reconstruction and level set interface tracking was implemented for CFD modeling, providing direct visualization of evolving refrigerant flow patterns. Distinct flow regimes were identified: a fully vapor, desuperheating region near the inlet (0–1.8 m), a condensation zone (1.8–6 m) marked by classic stratified and annular two-phase flow with a sharp decline in vapor void fraction and a near-constant temperature and a subcooled liquid zone (6–8.9 m) where the tube was completely filled with liquid. The presence and length of each regime were confirmed by 2D cross-sectional CFD images and experimental surface temperature profiles. Pointwise comparison of measured and simulated wall temperatures across all 41 positions yielded a Mean Absolute Error (MAE) of 1.46 °C and a Root Mean Square Error (RMSE) of 1.63 °C, validating the numerical approach. These findings demonstrate that the spatially resolved CFD model captures both the thermal and hydrodynamic developments throughout condensation, supporting more robust and energy-efficient condenser designs for the local operation. 

Keywords—R410A condensation, two-phase flow, vapor void fraction, experimental validation

Cite: Veyan A. Musa, Omar M. Ali, and Raid A. Mahmood, "Characterization and Validation of R410A Condensation Performance in Split Air Conditioning Units: Experimental Investigation and ANSYS Fluent Simulation," International Journal of Mechanical Engineering and Robotics Research, Vol. 14, No. 6, pp. 630-644, 2025. doi: 10.18178/ijmerr.14.6.630-644

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