DEsign and Production of Lattice structures for Optimized heat exchangers for sustainable mobilitY applications
ProjectDEPLOY aims to design, model and manufacture 3D lattice structures for heat exchange purposes,
to be produced by AM, thus pursuing mechanical resistance coupled with low weight, high surface
to-volume ratios and tuneable roughness.
Triply-Periodic Minimal Surfaces (TPMS) reticula will be investigated, with gyroid and Schwarz being
identified as the most promising ones.
AM allows the production of customized periodic cells with high geometrical degree of freedom.
Aluminium alloys are deemed to be suitable candidates for cooling/heating mechanical devices.
Thermo-mechanical properties and density of these materials can be adjusted by tuning the AM
process.
A microarchitected TPMS liquid-liquid compact heat exchanger will be targeted as a representative
case-study.
The project also aims to study the direction-dependent nature of conductivity and surface roughness,
as a result of AM. The two anisotropic features can in principle enable novel optimization
approaches. The heat exchanger can thus be engineered not only in terms of 3D shape and
void/solid distribution, but also as for direction-specific thermal properties and tuning of the surface
area.
From a thermo-structural standpoint, preliminary computational investigations will be pursued to
assess the feasibility of transitioning from traditional units to the optimized lattice parts: mechanical
and thermal properties will be evaluated, and the most suitable architectures will be selected to
perform stable, light and efficient devices.
Numerical optimization methods in synergy with Design for AM constraints will be applied to
determine the optimal final layout from micro-scale (unit periodic cell) to macro-scale (heat
exchanger/insulating shell) applications.
To determine the heat transfer performance, the most suitable modelling approaches will be selected
combining analytical models and numerical simulations, benefiting from a combination of pre-existing
data available in the open literature and the specific experience of the PI in the development of
original heat transfer models. Furthermore, the analysis of stiffness-to-weight and strength-to-weight
properties, mostly focused on lightweight design, will be conducted to evaluate the optimal size-to
thickness ratio of the TMPS structure thanks to proponents’ know-how.
Finally, the most promising unit cells will be used to manufacture prototypes of heat exchangers to
validate experimentally the numerical forecasts. A novel approach to investigate the effectiveness of
powder removal from inner cavities of the as-built part will be attempted via 3D-CFD, in order to
identify possible further design constraints.
The developed design and modelling approaches, together with the acquired dataset about
structural/geometrical properties and tests, are expected to spur the adoption of these structures in
mobility devices.
to be produced by AM, thus pursuing mechanical resistance coupled with low weight, high surface
to-volume ratios and tuneable roughness.
Triply-Periodic Minimal Surfaces (TPMS) reticula will be investigated, with gyroid and Schwarz being
identified as the most promising ones.
AM allows the production of customized periodic cells with high geometrical degree of freedom.
Aluminium alloys are deemed to be suitable candidates for cooling/heating mechanical devices.
Thermo-mechanical properties and density of these materials can be adjusted by tuning the AM
process.
A microarchitected TPMS liquid-liquid compact heat exchanger will be targeted as a representative
case-study.
The project also aims to study the direction-dependent nature of conductivity and surface roughness,
as a result of AM. The two anisotropic features can in principle enable novel optimization
approaches. The heat exchanger can thus be engineered not only in terms of 3D shape and
void/solid distribution, but also as for direction-specific thermal properties and tuning of the surface
area.
From a thermo-structural standpoint, preliminary computational investigations will be pursued to
assess the feasibility of transitioning from traditional units to the optimized lattice parts: mechanical
and thermal properties will be evaluated, and the most suitable architectures will be selected to
perform stable, light and efficient devices.
Numerical optimization methods in synergy with Design for AM constraints will be applied to
determine the optimal final layout from micro-scale (unit periodic cell) to macro-scale (heat
exchanger/insulating shell) applications.
To determine the heat transfer performance, the most suitable modelling approaches will be selected
combining analytical models and numerical simulations, benefiting from a combination of pre-existing
data available in the open literature and the specific experience of the PI in the development of
original heat transfer models. Furthermore, the analysis of stiffness-to-weight and strength-to-weight
properties, mostly focused on lightweight design, will be conducted to evaluate the optimal size-to
thickness ratio of the TMPS structure thanks to proponents’ know-how.
Finally, the most promising unit cells will be used to manufacture prototypes of heat exchangers to
validate experimentally the numerical forecasts. A novel approach to investigate the effectiveness of
powder removal from inner cavities of the as-built part will be attempted via 3D-CFD, in order to
identify possible further design constraints.
The developed design and modelling approaches, together with the acquired dataset about
structural/geometrical properties and tests, are expected to spur the adoption of these structures in
mobility devices.