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Title: Additive Manufacturing for Cost Efficient Production of Compact Ceramic Heat Exchangers and Recuperators

An additive manufacture technique known as laminated object manufacturing (LOM) was used to fabricate compact ceramic heat exchanger prototypes. LOM uses precision CO2 laser cutting of ceramic green tapes, which are then precision stacked to build a 3D object with fine internal features. Modeling was used to develop prototype designs and predict the thermal response, stress, and efficiency in the ceramic heat exchangers. Build testing and materials analyses were used to provide feedback for the design selection. During this development process, laminated object manufacturing protocols were established. This included laser optimization, strategies for fine feature integrity, lamination fluid control, green handling, and firing profile. Three full size prototypes were fabricated using two different designs. One prototype was selected for performance testing. During testing, cross talk leakage prevented the application of a high pressure differential, however, the prototype was successful at withstanding the high temperature operating conditions (1300 °F). In addition, analysis showed that the bulk of the part did not have cracks or leakage issues. This led to the development of a module method for next generation LOM heat exchangers. A scale-up cost analysis showed that given a purpose built LOM system, these ceramic heat exchangers would be affordable formore » the applications.« less
Authors:
 [1] ;  [1]
  1. Ceralink Incorporated, Troy, NY (United States)
Publication Date:
OSTI Identifier:
1234436
DOE Contract Number:
FE0024066
Resource Type:
Technical Report
Research Org:
Ceralink Incorporated, Troy, NY (United States)
Sponsoring Org:
USDOE
Country of Publication:
United States
Language:
English
Subject:
01 COAL, LIGNITE, AND PEAT; 36 MATERIALS SCIENCE; 42 ENGINEERING; 99 GENERAL AND MISCELLANEOUS