4046 AM of Heat Exchanges for Propulsion Applications

This project seeks to develop a heat exchanger (HEX) design that best addresses thermal fatigue, envelope optimization, pressure drop, flow distribution, and thermal performance. The HEX will be built and validated using laser powder bed fusion additive manufacturing (PBFAM).

Problem
Objective
Technical Approach
Project Participants
Problem

The continuous demand for increased turbine inlet temperature requires cooling of the air in the high pressure turbine to lower the disk and seal plate temperatures to acceptable levels. The use of additive manufacturing (AM) for these components offers compelling design freedoms not available with subtractive manufacturing techniques. Such application would be particularly beneficial for military engine programs.

Objective

The objective of this program is to develop unique powder bed fusion additive manufacturing (PBFAM) designs for heat exchangers that would not be possible or cost-effective using conventional fabrication. The project seeks to employ in situ process sensing, process control, qualification, and statistical mechanical testing of AM built components.

Technical Approach

Honeywell and 3D Systems (3DS) will add the Pennsylvania State University— Applied Research Laboratory (ARL) process sensors to one of each of their machines, with the Honeywell installation at its Phoenix AM facility and the 3DS installation at ARL. Each system will be used to perform a design of experiments to optimize the build parameters for the heat exchanger, with defects incorporated into select components to assess the sensing strategies. The systems with the optimized parameters will then be used to build a heat exchanger that will be tested at Honeywell’s Torrance, CA facility. Another set of heat exchangers will be sent to AFRL for testing and evaluation.

Project Participants

Project Principal

Other Project Participants

  • 3D Systems
  • Penn State ARL

Public Participants

  • U.S. Department of Defense
  • National Science Foundation
  • U.S. Department of Energy
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