Air-to-Liquid Heat Exchanger Fabricated Using Deposition-Based Additive Manufacturing Processes

Boxleitner, Jake; Mulholland, Tom; Nellis, Gregory

doi:10.1115/1.4054447

Air-to-Liquid Heat Exchanger Fabricated Using Deposition-Based Additive Manufacturing Processes

Journal Article · 05 September 2022 · Journal of Thermal Science and Engineering Applications

DOI:https://doi.org/10.1115/1.4054447· OSTI ID:2418386

Boxleitner, Jake ^[1]; Mulholland, Tom; Nellis, Gregory

OSTI

Abstract

This work describes the use of deposition-based additive manufacturing (AM) techniques to fabricate air-cooled, two-fluid heat exchangers. The project focused on a Heating, Ventilation and Air Conditioning application and used an industry-standard copper/aluminum heat exchanger manufactured with conventional technology as the basis for assessing performance. The manufacturing constraints associated with using deposition-based AM technology for this application include the need for a continuous tool path within each build layer that allows uninterrupted extrusion and therefore defect-free water channel walls that correspond to a reliably leak-tight heat exchanger. A geometry that respects these constraints was developed, simulated, optimized and finally manufactured and tested. The material used was a composite of polymer filled with conductive flakes in order to provide high conductivity in the direction that heat must flow in this heat exchanger, across the wall separating the fluids. The measured performance for several test coupons matched the predicted performance and the test coupons exhibited performance that approach and in some cases exceeds conventional technology

Research Organization:: Univ. of Wisconsin, Madison, WI (United States)

Sponsoring Organization:: USDOE Advanced Research Projects Agency - Energy (ARPA-E)

DOE Contract Number:: AR0000573

OSTI ID:: 2418386

Journal Information:: Journal of Thermal Science and Engineering Applications, Journal Name: Journal of Thermal Science and Engineering Applications Journal Issue: 12 Vol. 14; ISSN 1948-5085

Publisher:: ASME

Country of Publication:: United States

Language:: English

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