Additive Manufacturing of a High Temperature, Ni-Based Superalloy Compact Heat Exchanger: A Study on the Role of Select Key Printing ParametersSource: ASME Journal of Heat and Mass Transfer:;2023:;volume( 145 ):;issue: 004::page 41901-1Author:Battaglia, Fabio
,
Zhang, Xiang
,
Arie, Martinus A.
,
Shooshtari, Amir
,
Sarmiento, Andres Paul
,
Ohadi, Michael
DOI: 10.1115/1.4056484Publisher: The American Society of Mechanical Engineers (ASME)
Abstract: Compared to state-of-the-art heat exchangers, manifold-microchannel heat exchangers have shown superior heat removal density (kW/kg) at moderate pressure drops. However, manifold-microchannel heat exchangers made of Ni-based superalloys or other tough-to-machine materials can be a challenge to fabricate using conventional fabrication methods. This is mainly because of the inherently complex manifold microchannel geometry, as well as the required small feature sizes (e.g., fin thickness) that should be comparable, or smaller than state-of-the-art high-performance metallic-based heat exchangers (∼150 μm or smaller). In this study, a direct metal laser sintering (DMLS) additive manufacturing technique was used to fabricate the compact high-temperature manifold-microchannel heat exchanger reported here. The additively manufactured manifold-microchannel heat exchanger was fabricated as a single object, which significantly simplifies the fabrication process. In this work, three different additive manufacturing machines were used to study the effect of laser power, powder size, and layer thickness on the fin and channel sizes of the fabricated microchannel heat exchangers. To evaluate the minimum wall thickness for holding the required design pressures, pressure containment tests were performed. As a result, a wall thickness of 0.3 mm was shown to withstand 340 kPa and be leakage-free. A detailed analysis of different printing orientations and their effect on the manifold-microchannel heat exchanger's design was also performed. Finally, a 76 × 76 × 76 mm3 manifold microchannel heat exchanger was successfully fabricated with a fin thickness of 0.13 mm out of maraging steel. A second unit with dimensions of 94 × 87.6 × 94.4 mm3 was successfully fabricated with a fin thickness of 0.22 mm out of Inconel 718. Details of the fabrication process and key take-away results are discussed in this paper.
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contributor author | Battaglia, Fabio | |
contributor author | Zhang, Xiang | |
contributor author | Arie, Martinus A. | |
contributor author | Shooshtari, Amir | |
contributor author | Sarmiento, Andres Paul | |
contributor author | Ohadi, Michael | |
date accessioned | 2023-11-29T18:44:43Z | |
date available | 2023-11-29T18:44:43Z | |
date copyright | 1/4/2023 12:00:00 AM | |
date issued | 1/4/2023 12:00:00 AM | |
date issued | 2023-01-04 | |
identifier issn | 2832-8450 | |
identifier other | ht_145_04_041901.pdf | |
identifier uri | http://yetl.yabesh.ir/yetl1/handle/yetl/4294361 | |
description abstract | Compared to state-of-the-art heat exchangers, manifold-microchannel heat exchangers have shown superior heat removal density (kW/kg) at moderate pressure drops. However, manifold-microchannel heat exchangers made of Ni-based superalloys or other tough-to-machine materials can be a challenge to fabricate using conventional fabrication methods. This is mainly because of the inherently complex manifold microchannel geometry, as well as the required small feature sizes (e.g., fin thickness) that should be comparable, or smaller than state-of-the-art high-performance metallic-based heat exchangers (∼150 μm or smaller). In this study, a direct metal laser sintering (DMLS) additive manufacturing technique was used to fabricate the compact high-temperature manifold-microchannel heat exchanger reported here. The additively manufactured manifold-microchannel heat exchanger was fabricated as a single object, which significantly simplifies the fabrication process. In this work, three different additive manufacturing machines were used to study the effect of laser power, powder size, and layer thickness on the fin and channel sizes of the fabricated microchannel heat exchangers. To evaluate the minimum wall thickness for holding the required design pressures, pressure containment tests were performed. As a result, a wall thickness of 0.3 mm was shown to withstand 340 kPa and be leakage-free. A detailed analysis of different printing orientations and their effect on the manifold-microchannel heat exchanger's design was also performed. Finally, a 76 × 76 × 76 mm3 manifold microchannel heat exchanger was successfully fabricated with a fin thickness of 0.13 mm out of maraging steel. A second unit with dimensions of 94 × 87.6 × 94.4 mm3 was successfully fabricated with a fin thickness of 0.22 mm out of Inconel 718. Details of the fabrication process and key take-away results are discussed in this paper. | |
publisher | The American Society of Mechanical Engineers (ASME) | |
title | Additive Manufacturing of a High Temperature, Ni-Based Superalloy Compact Heat Exchanger: A Study on the Role of Select Key Printing Parameters | |
type | Journal Paper | |
journal volume | 145 | |
journal issue | 4 | |
journal title | ASME Journal of Heat and Mass Transfer | |
identifier doi | 10.1115/1.4056484 | |
journal fristpage | 41901-1 | |
journal lastpage | 41901-12 | |
page | 12 | |
tree | ASME Journal of Heat and Mass Transfer:;2023:;volume( 145 ):;issue: 004 | |
contenttype | Fulltext |