This paper will describe a process for development and validation of plate-fin heat exchangers (HX) using metal additive manufacturing (AM) processes and Model Based Engineering (MBE). A literature review will be presented to address plate-fin heat exchanger design [1, 2], including experimentally derived non-dimensional (f &amp; Nu) correlations for heat transfer and pressure drop for offset-strip and wavy fins [3, 4]. An approach for designing and optimizing heat exchangers [5, 6] using commercial HX sizing and rating software will be presented. It leverages user-defined geometries and thermal performance data, and inlet conditions, to size HXs that can span a broad design space. CFD-based conjugate heat transfer analysis will also be presented for assessing novel heat exchanger concepts that deviate from the design space supported by published correlations. A closed-loop Design for AM (DfAM) method for thermal management devices is also presented. The DfAM approach starts with requirements definition and covers preliminary design, design optimization, model preparation for AM, build trials, experimental validation, and final part build.Recent breakthroughs in metal AM processes for HX and cold plate (CP) applications have been made. The paper will describe latest progress in AM-fabricated CP and HXs in aluminum, stainless steel, traditional nickel-based superalloys, and new superalloys developed specifically for AM processing. A key accomplishment that paves the way for unlocking the broad design latitude afforded by AM processing is the capability to print thin-walled metallic structures (e.g., fins), in the range of 125 to 175 microns. The paper will depict successful builds of metallic plate-fin HXs in traditional rectangular cuboid form factors and conformal form factors (e.g., annular). Experimental validation of these AM-fabricated metallic HX prototypes will be described, including demonstration of pressure containment (i.e., leak-tightness), isothermal pressure drop, and heat transfer testing. The measured HX thermal performance is compared to corresponding model predictions obtained using commercial software that implements applicable correlations for the selected heat transfer surfaces [3, 4].This paper will conclude by presenting an overview of steps required to bring metal AM heat exchangers and cold plates to a technical maturity of TRL 6 and an envisioned roadmap for adoption of this technology in aviation platforms.References:&nbsp;[1]&nbsp;R. Shah and D. Seklulic, Fundamentals of Heat Exchanger Design, Hoboken, NJ: John Wiley &amp; Sons, Inc., 2003.&nbsp;[2]&nbsp; A. L. London and R. K. Shah, "Offset Rectangular Plate-Fin Surfaces -- Heat Transfer and Flow Friction Characteristics," Trans. ASME, J. Eng. Power, no. 90, pp. 218-228, 1968.[3]&nbsp;R. M. Manglik and A. E. Bergles, "Heat Transfer and Pressure Drop Correlations for the Rectangular Offset-Strip Fin Compact Heat Exchanger," Experimental Thermal and Fluid Science, pp. 171-180, 1995.[4]&nbsp; M. M. Awad and Y. S. Muzychka, "Models for Pressure Drop and Heat Transfer in Air Cooled Compact Wavy Fin Heat Exchangers," Journal of Enhanced Heat Transfer, vol. 18, no. 3, pp. 191-207, 2011.[5]&nbsp; K. Kasim, A. Muley, M. Stoia and F. Ladeinde, "Advanced Heat Transfer Devices for Aerospace Applications," in ASME 2017 International Mechanical Engineering Congress and Exposition, 2017.[6]&nbsp;K. R. Saviers, R. Ranjan and R. Mahmoudi, "Design and Validation of Topology Optimized Heat Exchangers," in AIAA Scitech Forum, San Diego, CA, 2019.&nbsp;&nbsp;

Recent Advances in Thin-Wall Additively Manufactured Heat Exchangers

Paper Proceedings: https://asmedigitalcollection.asme.org/IMECE/IMECE2021/volume/85543

ASME 2021 International Mechanical Engineering Congress and Exposition (IMECE2021)

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