journal article·2021-11

Ultra-power-dense heat exchanger development through genetic algorithm design and additive manufacturing

Hyunkyu Moon, Davis J. McGregor, Nenad Miljkovic, William P. King

Joule· Volume 5· Issue 11
Publisher page

Abstract

Summary This work presents the design, fabrication, and characterization of a three-dimensional heat exchanger (HX) having a tube-in-tube architecture using a genetic algorithm design and metal additive manufacturing (AM). The genetic algorithm aids the design of optimal fin geometries that minimize total thermal resistance between hot fluid and cold fluid. The genetic algorithm is coupled to a two-dimensional finite element method simulation to calculate conduction and convection in the device. Through careful thermal-hydraulic experiments, we demonstrate that our HX was able to achieve a power density of 26.6 W/cm3 and specific power of 15.7 kW/kg. The specific power of our additively manufactured device is 20X higher than that of a commercially available tube-in-tube HX with no fins. The optimized device also performs well compared with shell-and-tube and brazed plate heat exchangers that are designed for significantly higher heat transfer.
Source: openaire · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Heat Transfer and Optimization · Building Energy and Comfort Optimization · Topology Optimization in Engineering

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (53)

Show source-provided references
1. Stone
2. The effect of additive manufacturing on global energy demand: an assessment using a bottom-up approach10.1016/j.enpol.2017.10.034 ↗
3. Effectively designed NTW shell-tube heat exchangers with segmental baffles using flow hydraulic network method10.1016/j.applthermaleng.2017.04.033 ↗
4. Heat transfer and pressure drop performance of twisted oval tube heat exchanger10.1016/j.applthermaleng.2012.06.037 ↗
5. An experimental investigation of heat transfer enhancement for a shell-and-tube heat exchanger10.1016/j.applthermaleng.2008.12.008 ↗
6. Experimental investigation on performance comparison for shell-and-tube heat exchangers with different baffles10.1016/j.ijheatmasstransfer.2014.12.071 ↗
7. Pressure drop and heat transfer study in tube-in-tube helical heat exchanger10.1016/j.ces.2006.01.039 ↗
8. Heat transfer enhancement and pressure drop characteristics of TiO2-water nanofluid in a double-tube counter flow heat exchanger10.1016/j.ijheatmasstransfer.2008.10.023 ↗
9. Kays · 2012
10. Effect of coil-wire insert on heat transfer enhancement and pressure drop of the horizontal concentric tubes10.1016/j.icheatmasstransfer.2006.01.020 ↗
11. Recent developments in enhanced heat transfer10.1007/s00231-011-0872-y ↗
12. Review of passive heat transfer augmentation techniques
13. Mills · 1999
14. Bergman · 2011
15. Heat transfer augmentation for the flow of a viscous liquid in circular tubes using twisted tape inserts10.1016/0017-9310(96)00039-7 ↗
16. Experimental investigation of laminar mixed convection in tubes with longitudinal internal fins10.1115/1.3250493 ↗
17. Heat transfer performance of internally finned tubes in turbulent flow10.1080/01457638008939566 ↗
18. Heat transfer in internally finned tubes10.1115/1.3450528 ↗
19. Effect of lateral fin profiles on turbulent flow and heat transfer performance of internally finned tubes10.1016/j.applthermaleng.2009.03.016 ↗
20. Thermodynamic optimization of tree-shaped flow geometries10.1016/j.ijheatmasstransfer.2005.11.016 ↗
21. A genetic algorithm for fin profile optimization10.1016/S0017-9310(96)00294-3 ↗
22. Topology optimization for heat conduction using generative design algorithms10.1007/s00158-016-1563-6 ↗
23. Topology optimization of a pseudo 3D thermofluid heat sink model10.1016/j.ijheatmasstransfer.2018.01.078 ↗
24. Topology optimization of microchannel heat sinks using a two-layer model10.1016/j.ijheatmasstransfer.2019.118462 ↗
25. Topology optimization for fluid-thermal interaction problems under constant input power10.1007/s00158-013-0887-8 ↗
26. Topology optimization approaches: A comparative review10.1007/s00158-013-0978-6 ↗
27. Bendsoe · 2013
28. Topology optimization of two fluid heat exchangers10.1016/j.ijheatmasstransfer.2020.120543 ↗
29. Heat transfer optimization in internally finned tubes under laminar flow conditions10.1016/S0017-9310(97)00209-3 ↗
30. Energy and cost optimization of a plate and fin heat exchanger using genetic algorithm10.1016/j.applthermaleng.2011.02.031 ↗
31. Review of utilization of genetic algorithms in heat transfer problems10.1016/j.ijheatmasstransfer.2008.11.015 ↗
32. Heat transfer enhancement of single-phase internal flows using shape optimization and additively manufactured flow structures10.1016/j.ijheatmasstransfer.2021.121510 ↗
33. Design optimization and validation of high-performance heat exchangers using approximation assisted optimization and additive manufacturing10.1080/23744731.2017.1333877 ↗
34. Additive manufacturing of compact manifold-microchannel heat exchangers utilizing direct metal laser sintering
35. Development of an additive manufacturing-enabled compact manifold microchannel heat exchanger10.1016/j.applthermaleng.2018.10.122 ↗
36. An additively manufactured metallic manifold-microchannel heat exchanger for high temperature applications10.1016/j.applthermaleng.2018.08.032 ↗
37. Design, additive manufacturing, and performance of heat exchanger with a novel flow-path architecture10.1016/j.applthermaleng.2020.115775 ↗
38. Air-side heat transfer enhancement utilizing design optimization and an additive manufacturing technique10.1115/1.4035068 ↗
39. State-of-the-art in heat exchanger additive manufacturing10.1016/j.ijheatmasstransfer.2021.121600 ↗
40. An investigation of a multi-layered oscillating heat pipe additively manufactured from Ti-6Al-4V powder10.1016/j.ijheatmasstransfer.2016.12.063 ↗
41. Thermal conductivity, density, viscosity, and Prandtl- numbers of Di- and triethylene glycol-water mixtures10.1002/bbpc.19850890716 ↗
42. Heat capacity of poly (ethylene glycol)-water mixtures: poly (ethylene glycol)-water interactions10.1016/0040-6031(90)80160-Z ↗
43. Charbonneau · 2002
44. 03/02554 Performance analysis of rectangular ducts with staggered square pin fins10.1016/S0140-6701(03)92683-X ↗
45. Pressure drop and heat transfer of square pin-fin arrays in in-line and staggered arrangements10.1016/j.ijheatmasstransfer.2006.10.028 ↗
46. Turbulent augmentation of internal convection over pins in staggered-pin fin arrays10.1115/1.1811090 ↗
47. Gibson · 2010
48. A general review of the Wilson plot method and its modifications to determine convection coefficients in heat exchange devices10.1016/j.applthermaleng.2007.04.004 ↗
49. A new heat transfer correlation for transition and turbulent fluid flow in tubes10.1016/j.ijthermalsci.2016.04.022 ↗
50. Comprehensive correlating equations for heat, mass and momentum transfer in fully developed flow in smooth tubes10.1021/i160061a021 ↗
51. Heat transfer in all pipe flow regimes: laminar, transitional/intermittent, and turbulent10.1016/j.ijheatmasstransfer.2008.07.009 ↗
52. Improvement of heat transfer by means of ultrasound: application to a double-tube heat exchanger10.1016/j.ultsonch.2012.04.001 ↗
53. Pressure drop and heat transfer characteristics of a titanium brazed plate-fin heat exchanger with offset strip fins10.1016/j.applthermaleng.2012.08.066 ↗