< Back to previous page

Project

A study on the possibilities of additive manufacturing (LPBF) as production process for heat transfer applications.

Producing micro and mini scale heat exchangers with three-dimensional features using highly conductive materials is very challenging and in many cases not possible or not economical with conventional and state-of-the-art manufacturing techniques. Given their capability of producing freeform and highly complex geometries, additive manufacturing (AM) techniques have the potential to optimize (s)HEX by enhancing heat transfer rates and/or minimizing the pressure drop along the channels [9]. Attempts have been made to use AM techniques such as Laser Powder Bed Fusion (LPBF) for heat exchanger devices, but processing copper or copper-alloys with this technique proved to be very challenging due to the high thermal conductivity and optical reflectivity. Moreover, metal parts produced by AM including LPBF currently have a very poor and difficult to control surface quality and due to the small dimensions, surface roughness can have a strong impact on the heat transfer [5]. In addition, small internal and external features cannot be accurately produced by LPBF, limiting its current use for sHEX applications with channels <1 mm. The complexity of numerical CFD simulations for micro or mini heat exchanger geometries remains unchanged, while in terms of manufacturing and experimental characterization, changes in device dimensions can create many challenges. As a consequence, the development of new types of smallscale heat exchangers requires a complex multi-disciplinary approach including research and development in design, simulation, manufacturing, and advanced non-contact characterization. This often hampers the progress in creating new and performant small-scale HEX. In this research project, three KU Leuven PI’s from the Mechanical Engineering Department with complementary expertise and knowledge, will join efforts to tackle the challenges mentioned above and to reveal the fundamental dependence of heat transfer properties on geometric structure dimensions and shape, surface properties, and material of small-scale heat exchangers (sHEX).

Date:20 Aug 2021 →  Today
Keywords:additive manufacturing, heat exchangers, metals, AM
Disciplines:Manufacturing processes, methods and technologies
Project type:PhD project