Design of a Thermo-Hydraulically Optimised Heat Exchanger for Production by Laser Powder Bed Fusion

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Original languageGerman
Pages129-148
Number of pages20
Publication statusPublished - 2023

Abstract

Additve Manufacturing (AM) offers the possibility to design and optimise Heat Exchangers (HX) in a completely new way, beyond the conventional types, which are limited by semi-finished products like pipes and plates. This paper starts with a short summary of the limitations of conventional Heat Exchangers along with possible solutions and potentials offered by AM of Heat Exchangers. A special focus is on the use of lattice structures to enhance heat transfer. A thermo-hydraulically optimised Heat Exchanger for AM by Laser Powder Bed Fusion (LPBF) is presented. Before designing the Heat Exchangers, considerations made are shown. This gas cooler was flow-optimised using CFD simulations and it has an internal lattice structure on the gas side. For a reference element of the structure used, the simulations show an enhancement in heat transfer between 187 and 266% compared to a plain tube. Finally, LPBF printed demonstrator Heat Exchangers and geometries are shown.

Keywords

    Additive manufacturing (AM), Heat exchanger (HX), Laser powder bed fusion (LPBF), Lattice structures, CFD simulation

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Design of a Thermo-Hydraulically Optimised Heat Exchanger for Production by Laser Powder Bed Fusion. / Kahlfeld, Robin; Meyer, Ina; Kabelac, Stephan et al.
2023. 129-148.

Research output: Contribution to conferencePaperResearchpeer review

Kahlfeld R, Meyer I, Kabelac S, Lachmayer R, Bode B, (ed.), Kaierle S, (ed.). Design of a Thermo-Hydraulically Optimised Heat Exchanger for Production by Laser Powder Bed Fusion. 2023. Epub 2022 Nov 13. doi: 10.1007/978-3-031-05918-6_9
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abstract = "Additve Manufacturing (AM) offers the possibility to design and optimise Heat Exchangers (HX) in a completely new way, beyond the conventional types, which are limited by semi-finished products like pipes and plates. This paper starts with a short summary of the limitations of conventional Heat Exchangers along with possible solutions and potentials offered by AM of Heat Exchangers. A special focus is on the use of lattice structures to enhance heat transfer. A thermo-hydraulically optimised Heat Exchanger for AM by Laser Powder Bed Fusion (LPBF) is presented. Before designing the Heat Exchangers, considerations made are shown. This gas cooler was flow-optimised using CFD simulations and it has an internal lattice structure on the gas side. For a reference element of the structure used, the simulations show an enhancement in heat transfer between 187 and 266% compared to a plain tube. Finally, LPBF printed demonstrator Heat Exchangers and geometries are shown.",
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author = "Robin Kahlfeld and Ina Meyer and Stephan Kabelac and Roland Lachmayer and Behrend Bode and Stefan Kaierle",
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T1 - Design of a Thermo-Hydraulically Optimised Heat Exchanger for Production by Laser Powder Bed Fusion

AU - Kahlfeld, Robin

AU - Meyer, Ina

AU - Kabelac, Stephan

AU - Lachmayer, Roland

A2 - Bode, Behrend

A2 - Kaierle, Stefan

N1 - Funded by the Ministry for Science and Culture of Lower Saxony (MWK) – School for Additive Manufacturing SAM

PY - 2023

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N2 - Additve Manufacturing (AM) offers the possibility to design and optimise Heat Exchangers (HX) in a completely new way, beyond the conventional types, which are limited by semi-finished products like pipes and plates. This paper starts with a short summary of the limitations of conventional Heat Exchangers along with possible solutions and potentials offered by AM of Heat Exchangers. A special focus is on the use of lattice structures to enhance heat transfer. A thermo-hydraulically optimised Heat Exchanger for AM by Laser Powder Bed Fusion (LPBF) is presented. Before designing the Heat Exchangers, considerations made are shown. This gas cooler was flow-optimised using CFD simulations and it has an internal lattice structure on the gas side. For a reference element of the structure used, the simulations show an enhancement in heat transfer between 187 and 266% compared to a plain tube. Finally, LPBF printed demonstrator Heat Exchangers and geometries are shown.

AB - Additve Manufacturing (AM) offers the possibility to design and optimise Heat Exchangers (HX) in a completely new way, beyond the conventional types, which are limited by semi-finished products like pipes and plates. This paper starts with a short summary of the limitations of conventional Heat Exchangers along with possible solutions and potentials offered by AM of Heat Exchangers. A special focus is on the use of lattice structures to enhance heat transfer. A thermo-hydraulically optimised Heat Exchanger for AM by Laser Powder Bed Fusion (LPBF) is presented. Before designing the Heat Exchangers, considerations made are shown. This gas cooler was flow-optimised using CFD simulations and it has an internal lattice structure on the gas side. For a reference element of the structure used, the simulations show an enhancement in heat transfer between 187 and 266% compared to a plain tube. Finally, LPBF printed demonstrator Heat Exchangers and geometries are shown.

KW - Additive manufacturing (AM)

KW - Heat exchanger (HX)

KW - Laser powder bed fusion (LPBF)

KW - Lattice structures

KW - CFD simulation

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