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International Heat Transfer Conference 16

ISSN: 2377-424X (online)
ISSN: 2377-4371 (flashdrive)

AN ADDITIVE MANUFACTURING-ENABLED AIR-TO-AIR HEAT EXCHANGER FOR HIGH TEMPERATURE APPLICATIONS

Xiang Zhang
Advanced Heat Exchangers and Process Intensification Laboratory, Department of Mechanical Engineering University of Maryland, College Park, MD 20742, USA

Farah Singer
Advanced Heat Exchangers and Process Intensification Laboratory, Department of Mechanical Engineering University of Maryland, College Park, MD 20742, USA

Amir H. Shooshtari
Advanced Heat Exchangers and Process Intensification Laboratory, Department of Mechanical Engineering University of Maryland, College Park, MD 20742, USA

Michael M. Ohadi
Small and Smart Thermal Systems Laboratory, Center for Energy Environmental Engineering, Department of Mechanical Engineering, University of Maryland, College Park, Maryland 20742, USA

DOI: 10.1615/IHTC16.her.023685
pages 4633-4640


PALABRAS CLAVE: Heat exchanger, Manufacturing, Heat transfer enhancement, 3-D printing, Air-to-air, High temperature

Sinopsis

Additive manufacturing has shown significant potential for design and construction of complex geometries and out of tough to machine materials such as those employed in high temperature applications. Aerospace industry can especially benefit from this technology for designing high temperature (> 650°C) heat exchangers which serve in diverse aircraft applications. However, significant research work is still needed to address some of the current challenges in 3-D printing of super alloys, including heat transfer surface finish, design of overhang structures, and manufacturing costs. Our recent optimization studies demonstrate a promising solution for a high temperature, cross-flow, air-to-air heat exchanger with enhanced heat transfer characteristics. The proposed manifold microchannel heat exchanger design utilizes additive manufacturing for fabrication of the heat exchanger. The optimization results indicate that the proposed 3-D printed heat exchanger can provide higher heat transfer capacity per unit mass characteristic (Q/m) when compared to conventional designs for the same mass flow rate, system pressure, and volume. In the current work, a subscale unit design was created by scaling down based on the full-scale design obtained in a previous work. To achieve the best 3-D printing quality, an inclined fin structure was considered in the design to avoid overhang structures. The fabricated unit was successfully 3-D printed as a single piece. To validate the numerical model, the fabricated unit was tested at the lower end temperatures of the cycle (~ 40°C), and the experimental results show a good agreement with the numerical predictions. The results highlight the potential of additive manufacturing for developing high temperature, high performance thermal systems for aerospace applications and beyond.

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