Session: 24-02 Additive Manufacturing Applications in Engines
Paper Number: 152868
Analysis of Additively Manufactured Cellular Structures As Heat Exchangers for Lightweight Designs in Electrified Propulsion Systems
The goal of net-zero aviation by 2050 led to the exploration of alternative propulsion concepts such as electric and hybrid-electric propulsion systems. Such electrified systems inevitably comprise of several electrical components which generate heat at different rates. The need to dissipate the heat from these components efficiently drives the researchers toward innovations in heat exchanger technology including light-weighting, incorporation of novel fins and cellular structures for achieving higher heat transfer rates. Furthermore, multi-functional heat exchangers, exhibiting load-withstanding mechanical properties, in addition to increased heat transfer are under research. This research paper focuses on studying mechanical performance of novel cellular structures based on Triply Periodic Minimal Surfaces (TPMS) geometries, both numerically and experimentally. The parameters defining the cellular structures in this study include porosity and geometrical parameters of unit cell size, strut diameter and connecting element thickness. These parameters are used to evaluate the key mechanical performance features including stiffness, compressibility, malleability, resistance to fracture. Different developed geometries are subjected to numerical simulations via Finite Element Method (FEM) to evaluate the key performance parameters with respect to different geometrical features. A few candidate geometries presenting favorable properties through the FEM analyses are experimentally tested. Within the scope of the experimental analysis, uni-axial tensile, compression, bending and shear tests are carried out. The material for 3D printing the geometries is considered as AlSi10Mg which is an ideal candidate for a heat exchanger application of the the cellular structures. The printing process utilizes the Selective Laser Melting method, followed by a heat treatment procedure to enhance material properties. The ongoing numerical analyses over a wide range of cellular geometries supported with the experiments will evaluate, in detail, the effect of geometrical features for such cellular structures on the mechanical performance. The outcome of this study can provide a helpful guideline to the complex heat exchanger designers, particularly in (hybrid-) electric aviation, where the multifunctionality of cellular structures is critical due to the high importance of weight and size optimization.
Presenting Author: George Luiz Rincaweski Vegini Brandenburgische Technische Universität Cottbus-Senftenberg
Presenting Author Biography: George Vegini holds a Master's degree in Mechanical and Aeronautical Engineering. He is currently working as an academic employee at the Brandenburg University of Technology, under the Chair of Aeroengine Design, where he is also pursuing his PhD. His main research areas include heat exchangers, thermal control, and hybrid electric propulsion.
Authors:
Akilan Mathiazhagan Brandenburgische Technische Universität Cottbus-SenftenbergGeorge Luiz Rincaweski Vegini Brandenburgische Technische Universität Cottbus-Senftenberg
Klaus Hoeschler Brandenburgische Technische Universität Cottbus-Senftenberg
Marco Montemurro Université de Bordeaux, Arts et M´etiers Institute of Technology CNRS, INRA
Majid Asli Brandenburgische Technische Universität Cottbus-Senftenberg
Karunakar Reddy Konda Brandenburgische Technische Universität Cottbus-Senftenberg
Analysis of Additively Manufactured Cellular Structures As Heat Exchangers for Lightweight Designs in Electrified Propulsion Systems
Paper Type
Technical Paper Publication