Highly Compact Metallic Heat Exchangers for Extreme ...
Transcript of Highly Compact Metallic Heat Exchangers for Extreme ...
Highly Compact Metallic Heat
Exchangers for Extreme
Environments (EEHX)
Dr. Ali Yousefiani
Boeing Research & Technology
Develop heat exchangers for use
in long-life sCO2 Brayton power
cycles, which can be employed in
high efficiency Integrated Power
& Thermal Management Systems
(IPTMS) for hypersonic aircraft
Project Vision
Project Overview
Historical Context:‣ BR&T has been developing EEHX (~800C) since 2008. Long history of development of performance enhanced
metallics using advanced bottom-up synthesis and manufacturing approaches. Subawardee on ARPA-E METALS
‣ UMD is world leader in broad HEX technology. UMD has been collaborating with BR&T on development of AM
aircraft engine precoolers (>500C) under ARPA-E ARID
‣ ATI is a global manufacturer of technically advanced specialty materials and complex components
‣ Metalysis has developed a unique technology (originally based on the Cambridge FFC® process) capable of
producing a vast range of metals and complex alloy powder feedstock at low cost
‣ AFRL is a world leader in refractory complex concentrated alloy development and characterization
Fed. funding: $2.4M
Length 30 mo.
Team member Location Role in project
Boeing Research & Technology (BR&T) CAManage program and lead materials, manufacturing processes and
EEHX development; T2M planning & TEA for aerospace market
University of Maryland (UMD) MD Lead topology optimization, EEHX testing, T2M for power generation
ATI NC Lead traditional feedstock production/characterization and AM tasks
Metalysis UK Lead nontraditional feedstock production/characterization
Air Force Research Laboratory (AFRL) OH Lead alloy selection and support development/characterization
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Innovation, Objectives, Final Deliverable
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Advanced Manufacturing: AM, PM, Hybrid AM-PM, SPF, and Novel Solid State Joining
Heat Transfer Flow Distribution
Advanced EEHX Design & Multi-Disciplinary Topological Optimization (MDTO)
Advanced Extreme Environment
Enhanced Superalloy and Complex
Concentrated Alloy Systems
AM
PM
FEM
BR&T Highly
Compact EEHX
• Builds on recent EEHX successes on ARPA-E &
DARPA funded programs (up to 800°C and 20 bar)
• Multi-disciplinary topologically optimized design
for long life (MTBF>40,000 hours) and efficient (ε >
82%) operationo Near-Term Market Entry 800C EEHX
o Advanced Topology Optimized 1000C EEHX
• Novel complex concentrated alloy systems that
will offer superior extreme environmental
durability and thermal/structural performance
supporting > 1000°C long term operation
• Hybrid combinations of additive/subtractive
fabrication, powder metallurgy processing,
advanced forming, and solid state joining to
address cost and manufacturability risks
BR&T’s Highly Compact and Tunable
Advanced EEHX Enables Next Generation
Power Systems with Ultra-High Efficiency
BR&T Highly Compact Extreme Environment Heat Exchanger
‣ Design
– Variable fins manifold-microchannel and primary surface heat exchanger configurations
– Low pressure drop due to improvements in flow distribution using manifolds
– Topology optimization will be used to improve EEHX power density
– Design for manufacturability is a key consideration
‣ Material
– Enhanced Superalloys – TRL5
– Extreme Environment Complex Concentrated Alloys –TRL2
‣ Manufacturing Process
– Hybrid combinations of additive and subtractive manufacturing, powder metallurgy, advanced forming, and solid state bonding
– Broad maturity range (TRL4 – TRL9)
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Conventional
Design Topology Optimized
Design
Task Outline
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Perform Manufacturing & Processing Trails, Test,
Evaluate, and Downselect
Alloy for 800C EEHX
Perform Manufacturing & Processing Trails, Test,
Evaluate, and Downselect
Alloy for 1000C EEHX
Define 800C
Material System Options
Produce Feedstock for 800C Alloy-1
Build AM Based 800C EEHX Coupons
Test/Evaluate 800C EEHX
Coupons and Select
Optimum Fabrication Approach
Produce Feedstock for 800C Alloy-2
Build Hybrid 800C EEHX Coupons
Produce Feedstock for 1000C Alloy-1
Build AM Based 1000C EEHX
Coupons
Produce Feedstock for 1000C Alloy-2
Build Hybrid 1000C EEHX
Coupons
Build, Test, & Evaluate Near-
Term Market Entry Prototype 800C
EEHX
Build, Test, & Evaluate Advanced
Topology Optimized
Prototype 1000C EEHX
Test/Evaluate 1000C EEHX
Coupons and Select
Optimum Fabrication Approach
Feedstock Selection, Production, Test, & Evaluation Manufacturing Process Selection EEHX Production, Test, & Evaluation
Feedstock Selection, Production, Test & Evaluation Manufacturing Process Selection EEHX Production, Test, & Evaluation
MDTO Tool Development and Prelim Design
Coupon Design and MDTO Model Validation
Detailed EEHX Coupon and Prototype Design
Prelim EEHX Design & Analysis for IPTMS
Define 1000C
Material System Options
Go/No-Go 2 Go/No-Go 3Go/No-Go 1
Anticipated Challenges and Potential Partnerships
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