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July 17, 2017Science and Technology for the Built EnvironmentOpen Access

Design optimization and validation of high-performance heat exchangers using approximation assisted optimization and additive manufacturing

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Authors

DBDaniel BacellarVAVikrant AuteZHZhiwei Huang

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Overview

Experimental and numerical study demonstrates over 50% reductions in size and pressure drop in finless heat exchangers, indicating major efficiency gains through additive manufacturing.

Key Points

  • Evaluate the thermal-hydraulic performance of small finless tubes and optimize their shape using automated numerical simulations and additive manufacturing to outperform microchannel heat exchangers.
  • Conducted numerical analyses on fin effectiveness across small tube characteristic lengths.
  • Implemented shape optimization leveraging automated computational fluid dynamics (CFD) and approximation-assisted optimization techniques.
  • Fabricated and experimentally tested a metal 3D-printed prototype (NTHX-001) to validate the computational predictions.
  • Optimized designs demonstrated greater than 50% reductions in size, material volume, and pressure drop relative to baseline microchannel heat exchangers.
  • Experimental testing of the 3D-printed prototype matched numerical simulations within less than 5% for capacity, 10% for air heat transfer coefficient, and 15% for air pressure drop.

Cite This Study

Bacellar et al. (2017) studied this question.

synapsesocial.com/papers/6a7e3e12dea41f5fbab7aff4https://doi.org/10.1080/23744731.2017.1333877
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