Lighter heat exchangers by additive manufacturing

Important results from the project

In this project, the header of a commercial air-to-air heat exchanger has been redesigned for manufacturing by additive manufacturing (AM). The objective is to produce compact headers with an optimum flow distribution capability by taking advantage of the design freedom offered by AM. The results demonstrate how new header designs can reduce the overall weight of the heat exchanger unit. The project results are scalable to different sizes and even types of heat exchangers.

Expected long term effects

In the project, a completely new header (prototype) was designed and produced by AM. The header design was adapted for a high-performance heat exchanger type. Two AM technologies were investigated. The flow distribution within the header was simulated and then experimentally measured. The simulation results showed a uniform distribution. Laboratory tests on the 3D printed header also confirmed the simulation results and showed that the header distributes the fluid to the heat exchanger without excessive pressure loss.

Approach and implementation

The project group consists of industrial (Höganäs AB and HEATEX AB) and academic partners (RISE IVF AB and Lund University) with complementary expertise. HEATEX is a manufacturer of heat exchangers and in this project, HEATEX sets the requirements on the final product and also performs the final evaluation. Lund University supports the project with knowledge in the field of fluid dynamics and heat transfer. RISE IVF, provides the project with competence in design and additive manufacturing. Höganäs, provides the project with powder and the correct alloy for this application.