Additive Ducted Heat Exchanger Headers for Lower Pressure Loss
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Solution Overview
Problem
Conventional ducted heat exchanger systems in gas turbine engines face issues with weight, cost, and aerodynamic efficiency due to uniform geometries, material expansion differences, and manufacturing limitations, which affect engine performance and lifespan.
Innovation Solution
The use of additively manufactured heat exchanger cores with contoured inlet and exit headers optimized through Computational Flow Dynamics, allowing for a 15-20% reduction in volume and improved aerodynamics, reducing weight and cost while mitigating thermal stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional manufacturing techniques are used for heat exchanger cores, then structural uniformity is achieved, but weight increases and aerodynamic efficiency decreases
Solution Approach 1:
The patent applies local quality by transitioning from uniform thickness heat exchanger cores to variable thickness cores with optimized material distribution. The additively manufactured headers feature non-uniform wall thickness and integrated flow path geometries that concentrate material only where structurally necessary, reducing overall weight while maintaining local strength requirements.
Solution Approach 2:
The patent utilizes curvature principles through additively manufactured contoured headers with optimized aerodynamic surfaces. The headers feature curved flow paths and streamlined geometries that reduce flow separation and pressure losses, improving aerodynamic efficiency compared to conventional straight-edged manifolds.
2Reliability
If dissimilar metals are used in heat exchanger construction, then material selection flexibility increases, but thermal stress and lifespan decrease
Solution Approach 1:
The patent applies homogeneity by constructing the entire heat exchanger system including headers and cores from the same material composition. This eliminates galvanic corrosion and thermal stress issues associated with dissimilar metal joints, while the additive manufacturing process provides the necessary design flexibility through digital modeling and process control.
3Productivity
If conventional heat exchanger geometries are used, then manufacturing simplicity is maintained, but volume and engine performance debit increase
Solution Approach 1:
The patent applies dimensional optimization through additively manufactured headers that utilize three-dimensional flow path routing. The headers feature vertical and diagonal flow paths that efficiently utilize nacelle volume, reducing the horizontal footprint while maintaining thermal exchange capacity. The integrated manifold design eliminates the need for separate connection components.
Solution Approach 2:
The patent merges the inlet and outlet header functions into integrated additively manufactured components that combine manifold distribution, flow conditioning, and structural support functions. This consolidation reduces the number of discrete parts and connection interfaces, reducing overall system volume while improving aerodynamic flow continuity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a more efficient and lightweight heat exchanger system with reduced pressure losses and optimized airflow, enhancing engine performance and extending the system's lifespan.
Implementation Method 1
heat exchanger system with a heat exchanger and associated equipment to exchange engine heat with airflow
Implementation Method 2
exchange engine heat with airflow
Implementation Method 3
contoured additively manufactured headers that have been optimized through Computational Flow Dynamics to provide an ideal aerodynamic geometry that minimizes flow separation and pressure losses
Data Source
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AI summary
A heat exchanger system includes an additively manufactured inlet header 96 upstream of, and in fluid communication with, the heat exchanger core 90 and an additively manufactured exit header 98 downstream of, and in fluid communication with, the heat exchanger core. A method of manufacturing a header for a ducted heat exchanger system for a gas turbine engine includes additively manufacturing a header with respect to a desired airflow therethrough.