Additive Manufacturing as a Solution to Challenges Associated with Heat Pipe Production

Abstract

The aim of this review is to present the recent developments in heat pipe production, which respond to the current technical problems related to the wide implementation of this technology. A novel approach in HP manufacturing is to utilise hi-tech additive manufacturing techniques where the most complicated geometries are fabricated layer-by-layer directly from a digital file. This technology might be a solution to various challenges that exist in HP production, i.e., (1) manufacturing of complex or unusual geometries HPs; (2) manufacturing complicated and efficient homogenous wick structures with desired porosity, uniform pore sizes, permeability, thickness and where the pores are evenly distributed; (3) manufacturing a gravity friendly wick structures; (4) high customisation and production time; (5) high costs; (6) difficulties in the integration of the HP into a unit chassis that enables direct thermal management of heated element and decrease its total thermal resistance; (7) high weight and material use of the part; (8) difficulties in sealing; (9) deformation of the flat shape HPs caused by the high pressure and uneven distribution of stress in the casing, among others.

Innovations in Axial Flux Permanent Magnet Motor Thermal Management for High Power Density Applications

“…Szymanski et al [140] developed an aluminum alloy ammonia HP with a hybrid sintered wick using DMLS.…”

“…The study also tested a variety of wick structures and compared densities and geometries. The authors noted that predicting the mechanical properties of these AM HPs is challenging, and research still needs to be done to understand these parameters [140].…”

Advanced Measurement and Visualization Techniques for High-Temperature Heat Pipe Experiments

“…Advanced manufacturing (AM) has introduced new techniques for novel design, fabrication, and instrumentation of HPs. The versatility of AM compared to traditional subtractive manufacturing techniques can address heat pipe challenges such as manufacturing unique geometries, complex porous wick structures, pore size and distribution, permeability thickness, thermal contact with chassis, sealing the casing and wick structures, and reduction in material, cost, and time for production of low volume components [25]. Preliminary investigations at INL of heat pipe design using digital light photoluminescence have demonstrated the capability to combine the porous wick and solid region within one component, optimization of internal pore structure and highlight the importance of digital light photoluminescence (DLP) printing and sintering parameters [26].…”

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