HELP

Heat Exchangers for Lightweighting in Propulsion

Reticulated structures based on TPMS (Triply Periodic Minimal Surfaces) are emerging as promising solutions for the design of highly efficient heat exchangers. The project has led to the development and validation of a proof-of-concept (PoC) prototype of an aluminum alloy heat exchanger, with a significant advancement in technology maturity level from TRL1 to TRL3. Starting from the multi-physical optimization of the unit cell through 3D CFD simulations, it was possible to identify an optimal geometric configuration capable of maximizing heat transfer and minimizing pressure drop.

Based on the numerical results, a physical prototype was created through Additive Manufacturing, with quality verification through microscopic analysis of critical areas and leak tests to meet functional requirements. The testing phase, conducted on a test bench adapted for the application, allowed for the validation of the thermofluid dynamic behavior of the component. Experimental measurements have confirmed the numerical predictions with good accuracy, with only slight discrepancies attributable to the variability of the working fluid properties.

The project also demonstrated the effectiveness of the developed numerical framework for the design of exchangers based on reticulated structures, confirming the validity of the 6 mm Gyroid as a particularly promising configuration. Communication activities have exceeded the expected objectives, with the publication of a high impact factor journal article and two additional papers under review. The interest of an automotive manufacturer in a possible industrial application testifies to the potential of the developed device.