Additive Heat Exchanger Microstructure Tuning for Creep and Fatigue
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional heat exchangers are overdesigned to withstand multiple failure modes, leading to increased size, weight, and cost, as they are susceptible to creep in headers and fatigue in the core, necessitating a more efficient manufacturing method.
Innovation Solution
The method involves generating a stereolithography file with varying parameters for different layers to create distinct microstructures in headers and cores, optimizing material strength and surface roughness through controlled laser parameters, such as orientation, speed, and power, to address creep and fatigue failure modes separately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional heat exchangers are overdesigned to withstand multiple failure modes, then reliability is improved, but weight increases
Solution Approach 1:
The patent applies different microstructures to different portions of the heat exchanger based on their specific failure modes. The header region receives a first microstructure optimized for creep resistance, while the core region receives a second microstructure optimized for fatigue resistance. This localized optimization allows each region to have the minimum necessary strength for its specific conditions, rather than overdesigning the entire component.
Solution Approach 2:
The patent changes material parameters (microstructure characteristics) at different locations within the heat exchanger. By varying the microstructure parameters in response to different failure mode risks, the design achieves optimal reliability-to-weight ratio for each region without unnecessary overdesign elsewhere.
2Reliability
If conventional heat exchangers are overdesigned to withstand multiple failure modes, then reliability is improved, but cost increases
Solution Approach 1:
The patent applies different microstructures to different portions of the heat exchanger based on their specific failure modes. The header region receives a first microstructure optimized for creep resistance, while the core region receives a second microstructure optimized for fatigue resistance. This localized optimization allows each region to have the minimum necessary strength for its specific conditions, rather than overdesigning the entire component.
Solution Approach 2:
The patent changes material parameters (microstructure characteristics) at different locations within the heat exchanger. By varying the microstructure parameters in response to different failure mode risks, the design achieves optimal reliability-to-weight ratio for each region without unnecessary overdesign elsewhere.
3Reliability
If conventional heat exchangers are overdesigned to withstand multiple failure modes, then reliability is improved, but size increases
Solution Approach 1:
The patent applies different microstructures to different portions of the heat exchanger based on their specific failure modes. The header region receives a first microstructure optimized for creep resistance, while the core region receives a second microstructure optimized for fatigue resistance. This localized optimization allows each region to have the minimum necessary strength for its specific conditions, rather than overdesigning the entire component.
Solution Approach 2:
The patent changes material parameters (microstructure characteristics) at different locations within the heat exchanger. By varying the microstructure parameters in response to different failure mode risks, the design achieves optimal reliability-to-weight ratio for each region without unnecessary overdesign elsewhere.
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
This approach reduces the likelihood of failure in heat exchanger components by optimizing material properties and structure, resulting in a more efficient and cost-effective unit without overdesign, while minimizing fluid pressure drop and enhancing material strength and fatigue resistance.
Implementation Method 1
Energy from an energy source is applied to a powdered material such that the powdered material fuses to form the first portion and the second portion of each of the plurality of layers
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method of manufacturing a component susceptible to multiple failure modes includes generating a stereolithography file including a geometry of the component. The geometry of the stereolithography file is divided into a plurality of layers (32). Each of the layers (32) includes a first portion and a second portion of the component. Energy from an energy source is applied to a powdered material such that the powdered material fuses to form the first portion and the second portion of each of the plurality of layers. Applying energy from the energy source to form the first portion of the plurality of layers (32) includes operating the energy source with a first set of parameters and applying energy from the energy source to form the second portion of the plurality of layers includes operating the energy source with a second set of parameters. The first set and second set of parameters are different.