SBIR-STTR Award

Additive Manufacturing (AM) processes, such as laser powder bed fusion, have enabled the construction of heat exchangers with custom form factors and unique internal geometries. Topology optimization (TO) takes advantage of these unique geometries to create flow structures that have increased heat transfer effectiveness and reduced pressure drop compared to standard heat exchanger channels. The Navy is interested in evaluating the promise of AM in thermal management system designs (specifically condenser designs) to meet the demands of next-generation shipboard technologies. However, fully realizing the benefits of AM requires the use of optimization algorithms, and such design tools are not readily available. Creare and our collaborators will create a TO design toolkit that will allow for the design of compact condensers based on state-of-the-art AM capabilities and Navy performance objectives. In the Phase I Base phase, we will adapt our teams existing TO codebase into an overall design toolkit for condensers. We will then utilize the toolkit to develop a preliminary condenser design for the Navy and compare performance to Creares state-of-the-art micro channel normal flow condenser. In Phase II, we will develop a detailed design and fabricate and test a full-scale 50 kW condenser.

Benefit:
Compact two-phase thermal management systems (TMSs) will be required for future, high-power systems on next-generation ships. Condensers and other heat exchangers created with AM can be designed to meet the unique spatial requirements of integrated TMSs. Applying TO will also increase the volumetric power of the condenser, potentially exceeding state-of-the-art condensers. Combined, AM and TO will enable compact TMSs for future Navy needs, as well as reducing the SWaP for existing systems.

Keywords:
condensers, condensers, topology optimization, additive manufacturing, Two-phase Thermal Management