Low-order-model-based design of additive-manufactured heat exchanger

Abstract This paper discusses a comprehensive approach to the design of an additive-manufactured heat exchanger for a high-temperature application. This manufacturing route is attractive because of the flexibility afforded in design, but there is a requirement for calibration of internal friction factors and heat transfer coefficients because of uncertainty regarding the characteristics of the manufactured internal surfaces. The design was informed by physics-based low-order models (total pressure loss model; conjugate heat transfer model) calibrated against experimental data. To extract heat transfer coefficients we use transient experiments performed over timescales for which the surfaces can be regarded as semi-infinite. The calibrated models are used to predict accurate performance characteristics for the heat exchanger. Experimental results for a prototype design were found to be in excellent agreement with the model over a wide operational range, validating both the design methodology and the utility of the particular design for the given application. Our process, though not unique, has wide applicability, has been conducted with considerable care, and will be of interest to those engaged in low-order-model-based heat exchanger design.