Analysis of Additively Manufactured Cellular Structures as Heat Exchangers for Lightweight Designs in Electrified Propulsion Systems

Abstract

Abstract. The goal of net-zero emission aviation by 2050 led to the exploration of alternative propulsion concepts such as electric and hybrid-electric propulsion systems. Such electrified systems generate heat at different rates, which needs to be managed skillfully and efficiently dissipated from the components. This requires novel heat exchanger technology, including light weighting, incorporation of novel fins and cellular structures to achieve higher heat transfer rates, and multifunctional heat exchangers exhibiting load-withstanding mechanical properties. This research paper focuses on studying the mechanical performance of cellular structures based on triply periodic minimal surfaces (TPMS) geometries, both numerically and experimentally. Mechanical performance characteristics, including stiffness, compressibility, and resistance to fracture, are investigated by varying different geometrical features. Some candidate geometries presenting favorable properties through the finite element method (FEM) analysis are experimentally tested through uniaxial tensile and compression tests with three-dimensional printed AlSi10 Mg specimens. The results indicate that hybrid geometries proposed in this study have better mechanical properties, better stress distribution, lighter weight, whilst also having better compactness and good weight performance. The outcome of this study can provide a helpful guide for the design of complex heat exchangers.