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Enhancement of heat exchanger performance using additive manufacturing of gyroid lattice structures

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Abstract

The main objective of this research is to investigate the capability of laser powder bed fusion (LPBF) to manufacture complex heat exchangers with gyroid-shaped channels. First, the gyroid’s geometric features are investigated including the network type, thickness, unit cell size, and aspect ratio. Computational fluid dynamics (CFD) were used to screen these designs based on their thermal and fluid dynamics performance. Then, the manufacturability of various AlSi10Mg gyroid designs is tested using the LPBF, and the microstructure was investigated for defects. Finally, five heat exchanger prototypes were manufactured using LPBF; four of them were based on gyroid designs, and the fifth one was a conventional design for comparison. A heat transfer analysis is performed to compare the performance of the heat exchangers using conjugate heat transfer (CHT) methods. It was found that manipulating the sheet gyroid thickness and aspect ratio can result in a reasonable tradeoff between air side and coolant side pressure drops while maintaining the same heat rejection value. The suggested process parameters were able to successfully print the gyroid heat exchanger cores with thicknesses higher than 0.2 mm successfully. The LPBF-fabricated gyroid heat exchangers outperformed the conventional design. This study paves the road to a new generation of crossflow heat exchanger designs.

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Funding

This work was supported by Fiat Chrysler Automobiles and Mitacs Canada (Mathematics of Information Technology and Complex Systems).

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Authors and Affiliations

  1. Production Engineering Department, Alexandria University, Alexandria, 21544, Egypt

    Dalia Mahmoud

  2. Department of Mechanical Engineering, McMaster University, 1280 Main Street West, Hamilton, ON, L8S 4L7, Canada

    Shekhar Rammohan Singh Tandel, Mohamed Elbestawi, Chan Ching & Mohamed Abdelnabi

  3. Department of Mechanical Engineering, University of Alberta, 9211-116 Street NW, Edmonton, AB, T6G 1H9, Canada

    Mostafa Yakout

  4. CRF-Fiat Research Center, Strada Torino 50, 10043, Orbassano, Torino, Italy

    Fabrizio Mattiello

  5. Stellantis, Via Biscaretti di Ruffia 90/A, 10135, Torino, Italy

    Stefano Paradiso

  6. Department of Mechanical and Industrial Engineering, University of Toronto, Toronto, ON, M5S 3G8, Canada

    Mohammed Zaher

  7. Department of Mechanical Power Engineering, Ain Shams University, Cairo, 11517, Egypt

    Mohammed Zaher

Authors
  1. Dalia Mahmoud
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  2. Shekhar Rammohan Singh Tandel
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  3. Mostafa Yakout
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  4. Mohamed Elbestawi
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  5. Fabrizio Mattiello
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  6. Stefano Paradiso
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  7. Chan Ching
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  8. Mohammed Zaher
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  9. Mohamed Abdelnabi
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Contributions

D. Mahmoud: conceptualization, methodology, software, validation, and writing-original draft. S.R.S. Tandel: conceptualization, methodology, software, formal analysis, and investigation. M. Yakout: methodology, investigation, validation, project administration, and writing-review and editing. M.A. Elbestawi: supervision, funding acquisition, and writing-review and editing. F. Mattiello and S. Paradiso: conceptualization and validation. C. Ching: resources and validation. M.H. Zaher: investigation, validation, and writing-review and editing. M. Abdelnabi: methodology.

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Correspondence to Dalia Mahmoud.

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Mahmoud, D., Tandel, S.R.S., Yakout, M. et al. Enhancement of heat exchanger performance using additive manufacturing of gyroid lattice structures. Int J Adv Manuf Technol 126, 4021–4036 (2023). https://doi.org/10.1007/s00170-023-11362-9

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