PFI-RP: Design and additive manufacturing of heat exchangers

University Of Wisconsin-Madison, Madison WI

Investigators

Abstract

The broader impact/commercial potential of this Partnerships for Innovation – Research Partnerships (PFI-RP) project is to improve energy efficiency for convection-related applications, ranging from automotive to aerospace, power conversion, refrigeration, and others. The project will develop advanced computational techniques to improve the performance of heat exchangers, advancing design and manufacturing techniques in the energy industry. This project will also foster the training of technology commercialization for graduate students, and research training for under-represented students in STEM disciplines. The proposed project integrates topology optimization and additive manufacturing for heat exchangers. Density-based topology optimization of conjugate heat transfer systems will be conducted in a high-performance computing environment. An adjoint approach will be used to obtain the sensitivity. We will use density gradient-based formulations to address overhang angle and support structure control. The resulting heat exchangers will be manufactured via a metallic additive process. Thermal-hydraulic and durability tests will be conducted to validate performance. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.