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Illinois researchers demonstrate extreme heat exchanger with additive manufacturing:
Used in most major industries – including energy, water, manufacturing, transportation, construction, electronic, chemical, petrochemical, agriculture and aerospace – heat exchangers transfer thermal energy from one medium to another.
For decades, heat exchanger designs have remained relatively unchanged. Recent advancements in 3D printing allow the production of three-dimensional exchanger designs previously thought impossible. These new and innovative designs operate significantly more effectively and efficiently but require specific software tools and design methods to manufacture the high-performance devices.
[...] "We developed shape optimization software to design a high-performance heat exchanger," said William King, professor of Mechanical Science and Engineering at The Grainger College of Engineering and co-study leader. "The software allows us to identity 3D designs that are significantly different and better than conventional designs."
The team started by studying a type of exchanger known as a tube-in-tube heat exchanger – where one tube is nested inside another tube. Tube-in-tube heat exchangers are commonly used in drinking water and building energy systems. Using a combination of the shape optimization software and additive manufacturing, the researchers designed fins (only made possible using metal 3D printing) internal to the tubes.
"We designed, fabricated and tested an optimized tube-in-tube heat exchanger," said Nenad Miljkovic, associate professor of Mechanical Science and Engineering and co-study leader. "Our optimized heat exchanger has about 20 times higher volumetric power density than a current state-of-the-art commercial tube-in-tube device."
Journal Reference:
Hyunkyu Moon, Davis J. McGregor, Nenad Miljkovic, et al. Ultra-power-dense heat exchanger development through genetic algorithm design and additive manufacturing (DOI: 10.1016/j.joule.2021.08.004)
(Score: 1, Interesting) by Anonymous Coward on Monday September 13 2021, @01:25PM (7 children)
It may be more efficient to 3D print shapes with fins or fingers inside heat exchanges. But, one little leak (a missing "pixel" in the printing process) and the whole thing is junk. Unless the leak happens to be external, it won't be repairable either.
Is 3D printing error free? (I don't know that answer).
(Score: 4, Insightful) by HiThere on Monday September 13 2021, @01:51PM (4 children)
Nothing is error free. The question to ask is "How low can the error rate be made?". But it's a good point.
I've no idea how low the error rate would need to be for this to be practical, but there are clearly places where a "single pixel" error wouldn't have severe effects. E.g. in the middle of the fins a pixel error wouldn't cause a leak, but might cause increased turbulence, and possibly not be significant. I doubt that the tube walls are one atom thick, so a single pixel error there would only slightly weaken the walls. And even a microscopic hole wouldn't be significant in many uses. Water has enough surface tension that it won't easily flow through a really small hole, or you could fill the hole with silicon wax.
Javascript is what you use to allow unknown third parties to run software you have no idea about on your computer.
(Score: 2) by FatPhil on Monday September 13 2021, @01:53PM
Great minds discuss ideas; average minds discuss events; small minds discuss people; the smallest discuss themselves
(Score: 0) by Anonymous Coward on Monday September 13 2021, @09:01PM (2 children)
> Nothing is error free.
Actually, your sentence *is* error free, but incorrect.
Nothing of any significant complexity is error free.
ftfy
(Score: 2) by HiThere on Tuesday September 14 2021, @12:56AM (1 child)
But by being in error, it is correct.
Javascript is what you use to allow unknown third parties to run software you have no idea about on your computer.
(Score: 0) by Anonymous Coward on Tuesday September 14 2021, @04:12AM
And therefore wrong.
(Score: 2) by looorg on Monday September 13 2021, @02:31PM
I don't think I have ever encountered something being error free. But there are a lot of different printers and processes and materials so there are a lot of combinations. It also matters greatly then how the model or item being printed is made up, is it a solid object or is a mesh or some kind. If it's more or less solid then things are probably going to be ok I would say, a missing "pixel" (whatever that is) shouldn't be an issue. Nothing is, usually, really going to be "single pixel" thin anyway. But I guess there could be a missing or bad segment printed somewhere that creates a weak spot, or if you will a spot for future failures. If it's some kind of mesh with holes or empty spaces inside it then I guess it could be more of an issue. Is the object using filler material that later gets washed away or is it printed that way from the start etc. There could be structural issues then as you print it. But it also comes down to material choice and the process, how much cooling is there in the printing process is it plastic (of some kind) or metal (of some kind).
Perhaps a bigger issue is that a lot of printed stuff is not very smooth but has a sort of texture to it. You can fix that one the outside but if you have gaps and empty spaces inside it might become more of an issue. Plus it looks fugly.
That said if it's fast and cheap to print you just print a replacement if it was deemed faulty and hope the next one is better. If the issue keeps repeating you start looking at the model and try and fix the issue. Unless it was somehow a vital part and it's failure just created some unfortunate cascade of events and things went boom. Extreme heat in that regard makes it sound like a possibility.
(Score: 0) by Anonymous Coward on Tuesday September 14 2021, @04:14AM
> a missing "pixel" in the printing process
And also, they do not explain in the article, what would happen if a frozen chicken were to be introduced into the heat exchanger at say, Mach 2 or higher.