Design and evaluation of an additively manufactured aircraft heat exchanger

Saltzman, David; Bichnevicius, Michael; Lynch, Stephen P.; Simpson, Timothy W.; Reutzel, Edward W.; Dickman, Corey J.; Martukanitz, R. P.

doi:10.1016/j.applthermaleng.2018.04.032

Cited by 117 publications

(31 citation statements)

References 27 publications

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“…Micro-heat exchangers (μHXs) are widely used in fields that require compact thermal energy transfer solutions, such as microelectronics, aerospace, bioengineering, automotive, refrigeration, and air conditioning [5][6][7]. Traditionally, μHXs are manufactured by micro-machining, diffusion bonding, stereolithography, or chemical etching, among other methods [6].…”

Section: Micro-heat Exchangermentioning

confidence: 99%

“…The performance of a μHX is normally evaluated by the heat transfer rate and the pressure drop. Saltzman et al [7] reported improvement in the heat transfer of an aircraft oil cooler by about 10% after switching from traditional manufacturing to AM. The friction factor which controls the pressure drop has been shown to be influenced by the surface roughness of the AM part [13].…”

Section: Micro-heat Exchangermentioning

confidence: 99%

“…As discussed in Section 1.3, one useful application of thin-wall structures is for heat exchangers, where surface roughness affects heat transfer [7]. The roughness parameter, developed interfacial area ratio S dr , was Table 1 Designed thickness in CAD of each single-bead thin wall and its corresponding process parameters.…”

Section: Surface Metrologymentioning

confidence: 99%

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Exploring the fabrication limits of thin-wall structures in a laser powder bed fusion process

Narra

Rollett

2020

Int J Adv Manuf Technol

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Although additive manufacturing (AM) is becoming increasingly popular for various applications, few studies have addressed design and potential problems in thin wall fabrication for the laser powder bed fusion (LPBF) process. In the LPBF process, rapid cooling induces thermal shrinkage, which in turn, results in high residual stress and complicates thin wall fabrication. The minimum wall thickness is limited by the parameters and machine settings while the dimensional accuracy is controlled by the powder size, scan strategy, and part geometry. The ability to fabricate thin-wall components is important for applications such as heat exchangers (HX). This study explores the performance of the LPBF process by fabricating thin walls with extreme geometries in different processing conditions and alloys using an EOS M290 LPBF machine. Results show that the material, part design, and scanning strategy contribute to the variation in thin wall dimensions. A maximum inclination angle of 60°and a minimum wall thickness of1 00 μm in Ti-6Al-4V, Inconel 718, and AlSi10Mg were achieved using optimized part design and processing conditions. The effects of part design and material on the thermal distortion and surface finish of thin walls were also investigated leading to a discussion on how the scan mode assigned by the EOS software affects design and fabrication. Additionally, synchrotron-based X-ray micro-tomography (μSXCT) was utilized to quantify the porosity in thin-wall structures and to correlate it with the integrity of the structures. Comprehensive design guidelines presented in this work can increase the success rate of fabricating thin-wall geometries. Keywords Additive manufacturing (AM). Laser powder bed fusion (LPBF). Thin wall. Design guidelines. Porosity. X-ray computed tomography (XCT) Abbreviations AM Additive manufacturing LPBF Laser powder bed fusion μSXCT Synchrotron-based X-ray micro-tomography CAD Computer-aided design μHX Micro-heat exchanger XCT X-ray computed tomography EDM Electrical discharge machining APS Advanced Photon Source

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Section: Micro-heat Exchangermentioning

confidence: 99%

Section: Micro-heat Exchangermentioning

confidence: 99%

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Exploring the fabrication limits of thin-wall structures in a laser powder bed fusion process

Narra

Rollett

2020

Int J Adv Manuf Technol

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“…Generally, it will increase with the increase of SHX efficiency and vary with the ambient temperature. Secondly, the cooling ability and exergy penalty rate of SHX can be estimated by Equations (32) and (37), corresponding results under Cases 11~15 are shown as Figure 12b,c. Generally, the cooling ability of SHX which is inversely proportional to the skin temperature will increase with the increase of SHX efficiency.…”

Section: Skin Hxsmentioning

confidence: 99%

“…The second way to optimize the TMS is to improve the thermal management efficiency through more rational structure, more efficient heat transfer method or advanced control strategies/ algorithms. The improvement of HX is one of the effective methods, which cannot only improve the thermal management ability but also reduce the weight of a TMS [32,33]. Similarly, the improvement of fuel pumps is another effective method: a "variable speed pump system" has been proposed by Daisuke and Yukinori [34] which can reduce the energy consumption of the fuel recirculation system.…”

Section: Introductionmentioning

confidence: 99%

Cooling Ability/Capacity and Exergy Penalty Analysis of Each Heat Sink of Modern Supersonic Aircraft

Mao

Wang

et al. 2019

Entropy

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The aerospace-based heat sink is defined as a substance used for dissipating heat generated by onboard heat loads. They are becoming increasingly scarce in the thermal management system (TMS) of advanced aircraft, especially for supersonic aircraft. In the modern aircraft there are many types of heat sinks whose cooling abilities and performance penalties are usually obviously different from each other. Besides, the cooling ability and performance penalty of a single heat sink is even different under different flight conditions—flight altitude, Mach number, etc. In this study, the typical heat sinks which are the fuel mass, ram air, engine fan air, skin heat exchanger, and expendable heat sink will be studied. Their cooling abilities/capacities, and exergy penalties under different flight conditions have been systematically estimated and compared with each other. The exergy penalty presented in this paper refers to the exergy loss of aircraft caused by the extra weight, drag and energy extraction of various heat sinks. The estimation models, as well as the results and discussion have been elaborated in this paper, which can be can be used to further optimize the TMS of modern advanced aircraft, for example, the layout design of various heat sinks and the improvement the control algorithm.

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Design and development of a novel additively manufactured geothermal heat exchanger

Kabirnajafi

Gemeda

Demisse

et al. 2021

Intl J of Energy Research

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Design and evaluation of an additively manufactured aircraft heat exchanger

Cited by 117 publications

References 27 publications

Exploring the fabrication limits of thin-wall structures in a laser powder bed fusion process

Exploring the fabrication limits of thin-wall structures in a laser powder bed fusion process

Cooling Ability/Capacity and Exergy Penalty Analysis of Each Heat Sink of Modern Supersonic Aircraft

Design and development of a novel additively manufactured geothermal heat exchanger

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