Additively manufactured heat exchangers: a review on opportunities and challenges
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CRITICAL REVIEW
Additively manufactured heat exchangers: a review on opportunities and challenges Seyed A. Niknam 1
&
Mehdi Mortazavi 2 & Dongsheng Li 3
Received: 12 June 2020 / Accepted: 9 November 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Heat exchangers (HXs) are crucial engineering components for thermal management. The broad range of applications and the current limits of traditional manufacturing techniques have directed designers and researchers to utilize additive manufacturing (AM) technologies to open a new chapter in HX design and development. AM has created a world of opportunity to redesign HXs in pioneering forms, shapes, and sizes. The outstanding advantages of AM-enabled HXs include optimized geometries with enhanced surfaces, controlled surface roughness, fully controlled and organized porous structures, and eliminating the need for weld or braze. On the other hand, there are certain challenges to overcome in order to fully grasp the benefits of AM technologies. This thorough review study intends to highlight and elaborate the challenges and opportunities in design and manufacturing of HXs. In addition, part of this study is dedicated to investigate the experimental characterization of additively manufactured HXs. Keywords Heat exchanger . Additive manufacturing . Selective laser melting . Pin fin arrays . Surface roughness . Friction factor
1 Introduction Heat exchangers (HXs) are crucial components for thermal management. Exchanging heat between two fluids is the primary use of HXs, which creates applications in a broad range of engineering systems such as power plants, oil refineries, air conditioning, automotive, oil coolers in aircrafts, hightemperature resistojets, compact electronic cooling, chemical processes, waste heat recovery devices (e.g., recuperator) in furnaces and hydrogen plants, energy storage systems, and energy conversion systems such as refrigeration cycles [1–6]. For all practical purposes, the overall system reliability depends heavily on effective heat transfer [7]. There are distinct types of HXs based on process and operating environment [1] with the primary goal of maximum heat transfer as well as lowest pressure drop, i.e., pumping power
* Seyed A. Niknam [email protected] 1
Department of Industrial Engineering, Western New England University, Springfield, MA, USA
2
Department of Mechanical Engineering, Western New England University, Springfield, MA, USA
3
Advanced Manufacturing LLC, East Hartford, CT 06032, USA
consumptions [3]. Shell and tube HXs are the most common type of HXs for liquid-liquid applications. There are some concerns about the size and space limitation for this type of HXs, but innovations are underway [8, 9]. The other prevalent type of HXs is plate-and-frame which are normally applied for two liquids. Various patterns of plate and layout are being used in this type of HXs [4]. In essence, the HX specific application dictates its final type [10]. There are also various forms of passive heat transfer dev
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