“…The additive manufacturing process yields extremely rough surfaces [17], a consequence of the sintering process. One group of studies led by Jodoin [18][19][20] examined arrays of aluminum pyramidal pin fins that were manufactured additively via Cold Gas Dynamic Spraying. The authors collected bulk heat transfer data and reported good thermal performance coupled with high pressure losses.…”
Pin fin heat exchangers represent a common, viable means of keeping components cool and are widely used for electronics cooling and turbine airfoil cooling. Advancements in manufacturing technology will allow these heat exchangers to be built using new methods, such as laser powder bed fusion, a form of additive manufacturing. New manufacturing approaches, however, render a direct comparison between newly and conventionally manufactured parts meaningless without a good understanding of the difference in the performance. This research study investigated microchannel pin fin arrays that were manufactured using Laser Powder Bed Fusion and compared them to studies of pin fin arrays from the literature, which are representative of traditionallymanufactured pin fin arrays, where the pin and endwall surfaces exhibited much lower surface roughness. Pin fin arrays with four different spacings were manufactured and tested over a range of Reynolds numbers; pressure loss and heat transfer measurements were taken. Additionally, the test coupons were evaluated nondestructively and the asbuilt geometric features were analyzed. Measured surface roughness was found to be extremely high in each one of the microchannel pin fin arrays and was found to be a function of the pin spacing in the array, as was the shape of the pin itself; with more pins in the array came higher surface roughness and more distorted pin shapes. Comparisons between the smooth pin fin arrays from literature and the rough pin fin arrays from the current study showed that the high surface roughness more strongly affected the friction factor augmentation than it did the heat transfer augmentation relative to the smooth pin fin arrays.
“…The additive manufacturing process yields extremely rough surfaces [17], a consequence of the sintering process. One group of studies led by Jodoin [18][19][20] examined arrays of aluminum pyramidal pin fins that were manufactured additively via Cold Gas Dynamic Spraying. The authors collected bulk heat transfer data and reported good thermal performance coupled with high pressure losses.…”
Pin fin heat exchangers represent a common, viable means of keeping components cool and are widely used for electronics cooling and turbine airfoil cooling. Advancements in manufacturing technology will allow these heat exchangers to be built using new methods, such as laser powder bed fusion, a form of additive manufacturing. New manufacturing approaches, however, render a direct comparison between newly and conventionally manufactured parts meaningless without a good understanding of the difference in the performance. This research study investigated microchannel pin fin arrays that were manufactured using Laser Powder Bed Fusion and compared them to studies of pin fin arrays from the literature, which are representative of traditionallymanufactured pin fin arrays, where the pin and endwall surfaces exhibited much lower surface roughness. Pin fin arrays with four different spacings were manufactured and tested over a range of Reynolds numbers; pressure loss and heat transfer measurements were taken. Additionally, the test coupons were evaluated nondestructively and the asbuilt geometric features were analyzed. Measured surface roughness was found to be extremely high in each one of the microchannel pin fin arrays and was found to be a function of the pin spacing in the array, as was the shape of the pin itself; with more pins in the array came higher surface roughness and more distorted pin shapes. Comparisons between the smooth pin fin arrays from literature and the rough pin fin arrays from the current study showed that the high surface roughness more strongly affected the friction factor augmentation than it did the heat transfer augmentation relative to the smooth pin fin arrays.
“…-Alternating configurations produce higher convection coefficients and higher pressure drop.. [178] LIGA -The cross-flow micro heat exchanger was developed to provide a function similar to that of a car radiator.…”
Section: Heat Exchangers Using 3d Printing Technologymentioning
In just a few short years, the additive manufacturing (AM) technology known as 3D printing has experienced intense growth from a niche technology to a disruptive innovation that has captured the imagination of mainstream manufacturers and hobbyists alike. The purpose of this article is to introduce the use of 3D printing for specific applications, materials, and manufacturing processes that help to optimize heat transfer in heat exchangers, with an emphasis on sustainability. The ability to create complex geometries, customize designs, and use advanced materials provides opportunities for more efficient and stable heat transfer solutions. One of the key benefits of incremental technology is the potential reduction in material waste compared to traditional manufacturing methods. By optimizing the design and structure of heat transfer components, 3D printing enables lighter yet more efficient solutions and systems. The localized manufacturing of components, which reduces the need for intensive transportation and associated carbon emissions, can lead to reduced energy consumption and improved overall efficiency. The customization and flexibility of 3D printing enables the integration of heat transfer components into renewable energy systems. This article presents the key challenges to be addressed and the fundamental research needed to realize the full potential of incremental manufacturing technologies to optimize heat transfer in heat exchangers. It also presents a critical discussion and outlook for solving global energy challenges through innovative incremental manufacturing technologies in the heat exchanger sector.
“…Lamination AM is currently not compatible with multi-axis robotic systems, eliminating it from consideration. Cold-spray AM is compatible with robotic systems but lacks the ability to create complex parts without special equipment, and significant post-processing [167–169]. Thus it was not considered in this work. Figure 4. Various AM DED technologies: (a) GMAW, (b) PTAW and (c) LDED.…”
Additive Manufacturing (AM) has the potential to completely reshape the manufacturing space by removing the geometrical constraints of commercial manufacturing and reducing component lead time, especially for large-scale parts. Coupling robotic systems with direct energy deposition (DED) additive manufacturing techniques allow for support-free printing of parts where part sizes are scalable from sub-metre to multi-metre sizes. This paper offers a holistic review of large-scale robotic additive manufacturing, beginning with an introduction to AM, followed by different DED techniques, the compatible materials and their typical as-built microstructures. Next, the multitude of robotic build platforms that extend the deposition from the standard 2.5 degrees of freedom (DOF) to 6 and 8 DOF is discussed. With this context, the decomposition and slicing of the computerized model will be described, and the challenges of planning the deposition trajectory will be discussed. The different modalities to monitor and control the deposition in an attempt to meet the geometrical and performance specifications are outlined and discussed. A wide range of metals and alloys have been reported and evaluated for large-scale AM parts. These include steels, Ti, Al, Mg, Cu, Ni, Co-Cr and W alloys. Different post-processing steps, including heat treatments, are discussed, along with their microstructures. This paper finally addresses the authors' perspective on the future of the field and the largest knowledge gaps that need to be filled before the commercial implementation of robotic AM.
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