Additive manufacturing of heat exchangers: A case study on a multi-layered Ti–6Al–4V oscillating heat pipe

Thompson, Scott M.; Aspin, Zachary S.; Shamsaei, Nima; Elwany, Alaa; Bian, Linkan

doi:10.1016/j.addma.2015.09.003

Cited by 78 publications

(33 citation statements)

References 62 publications

(84 reference statements)

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“…was manufactured layer-by-layer atop a 10 x 10 x 1 cm 3 titanium platen within an argon purged L-PBF system (ProX 100™) equipped with a 50 W fiber laser [44]. Using Eq.…”

Section: Prototype Design and Manufacturingmentioning

confidence: 99%

An investigation of a multi-layered oscillating heat pipe additively manufactured from Ti-6Al-4V powder

Ibrahim

Monroe

Thompson

et al. 2017

International Journal of Heat and Mass Transfer

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A laser powder bed fusion (L-PBF) additive manufacturing (AM) method was employed for fabricating a multi-layered, Ti-6Al-4V oscillating heat pipe (ML-OHP). The 50.8 x 38.1 x 15.75 mm 3 ML-OHP consisted of four interconnected layers of circular mini-channels, as well an integrated, hermetic-grade fill port. A series of experiments were conducted to characterize the ML-OHP thermal performance by varying power input (up to 50 W), working fluid (water, acetone, Novec TM 7200, and n-pentane), and operating orientation (vertical bottom-heating, horizontal, and vertical top-heating). The ML-OHP was found to operate effectively for all working fluids and orientations investigated, demonstrating that the OHP can function in a multilayered form, and further indicating that one can 'stack' multiple, interconnected OHPs within flat media for increased thermal management. The ML-OHP evaporator size was found to depend on the layer-wise heat penetration which subsequently depends on power input and the ML-OHP design and material selection. Using neutron radiography, electron scanning microscopy and surface metrology, the ML-OHP channel structure was characterized and found to possess partially-sintered Ti-6Al-4V powder along its periphery. The partially-sintered channel surface, although a byproduct of the L-PBF manufacturing process, was found to behave as a secondary wicking structure for enhanced capillary pumping and wall/fluid heat transfer within the OHP. With the newfound capabilities of AM, many high heat flux thermal management devices, specifically those that employ mini-or micro-channels, can be 're-invented' to possess embedded channels with atypical geometries, arrangements and surface conditions.

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“…was manufactured layer-by-layer atop a 10 x 10 x 1 cm 3 titanium platen within an argon purged L-PBF system (ProX 100™) equipped with a 50 W fiber laser [44]. Using Eq.…”

Section: Prototype Design and Manufacturingmentioning

confidence: 99%

An investigation of a multi-layered oscillating heat pipe additively manufactured from Ti-6Al-4V powder

Ibrahim

Monroe

Thompson

et al. 2017

International Journal of Heat and Mass Transfer

Self Cite

View full text Add to dashboard Cite

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“…In the last few years, the use of components produced through additive manufacturing (AM) processes is rapidly growing in many industrial applications. AM parts are currently employed in applications subjected to static loads at room and high temperature [1,2], such as brackets [3], medical devices [4], or heat exchangers [5]; however, their use is still limited for applications subjected to fatigue loads [6,7]. Among the employed alloys, the ones belonging to the Al-Si system are drawing considerable interest thanks to their good mechanical properties and low density.…”

Section: Introductionmentioning

confidence: 99%

VHCF Response up to 109 Cycles of SLM AlSi10Mg Specimens Built in a Vertical Direction

et al. 2019

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It is well-known that many manufacturing parameters affect the quasi-static and the fatigue response of additive manufacturing (AM) parts. In particular, due to the layer-by-layer production, the load orientation, with respect to the building direction, plays a fundamental role for the fatigue response. This paper investigates the fatigue response up to 10 9 cycles (very high cycle fatigue (VHCF)) of selective laser melting (SLM) AlSi10Mg specimens built in a vertical direction. Ultrasonic tension-compression tests (stress ratio of -1) are carried out on as-built Gaussian specimens with a large loaded volume (2300 mm 3 ). Fracture surfaces are investigated with the scanning electron microscope to analyze the defects originating the VHCF failure. Probabilistic S-N curves are estimated and analyzed. Experimental results confirm that the defect size controls the VHCF response, thus highlighting the importance of testing large risk volumes for a reliable assessment of VHCF behavior. The average value of the VHCF strength is close to that of the hourglass specimen tested in the literature. The variability of the VHCF strength is instead significantly larger, due to the scattered size distribution of the defects located near the specimen surface, which is the most critical region for crack initiation.

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“…However, the fabrication of customized hollow conductors through conventional approaches can be challenging until AM has been introduced into this space [35], [36]. Even with AM, pure copper with high thermal conductivity can reflect the heat applied by a laser beam (I am not sure I understand this sentence).…”

Section: Customized Form Winding or Hollow Conductors 1) Customizementioning

confidence: 99%

Towards Fully Additively-Manufactured Permanent Magnet Synchronous Machines: Opportunities and Challenges

El-Refaie

2019

2019 IEEE International Electric Machines &Amp; Drives Conference (IEMDC)

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With the growing interest in electrification and as hybrid and pure electric powertrains are adopted in more applications, electrical machine design is facing challenges in terms of meeting very demanding performance metrics for example high specific power, harsh environments, etc. This provides clear motivation to explore the impact of advanced materials and manufacturing on the performance of electrical machines. This paper provides an overview of additive manufacturing (AM) approaches that can be used for constructing permanent magnet (PM) machines, with a specific focus on additivelymanufactured iron core, winding, insulation, PM as well as cooling systems. Since there has only been a few attempts so far to explore AM in electrical machines (especially when it comes to fully additivelymanufactured machines), the benefits and challenges of AM have not been comprehensively understood. In this regard, this paper offers a detailed comparison of multiple multi-material AM methods, showing not only the possibility of fully additively-manufactured PM machines but also the potential significant improvements in their mechanical, electromagnetic and thermal properties. The paper will provide a comprehensive discussion of opportunities and challenges of AM in the context of electrical machines.

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Additive manufacturing of heat exchangers: A case study on a multi-layered Ti–6Al–4V oscillating heat pipe

Cited by 78 publications

References 62 publications

An investigation of a multi-layered oscillating heat pipe additively manufactured from Ti-6Al-4V powder

An investigation of a multi-layered oscillating heat pipe additively manufactured from Ti-6Al-4V powder

VHCF Response up to 109 Cycles of SLM AlSi10Mg Specimens Built in a Vertical Direction

Towards Fully Additively-Manufactured Permanent Magnet Synchronous Machines: Opportunities and Challenges

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