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Additive Manufacturing
By utilising CT scanning and our proprietary software Conflux Quantify , we assess our parts for quality , porosity and other attributes . An essential step in proving the consistency of complex parts .
Managing heat transfer in these small scale solutions currently employ more modern , “ compact ” industrial heat exchangers like welded plate or printed circuit heat exchangers ( PCHE ). These are robust units also made using traditional manufacturing or diffusion bonding , where layers of etched metal are compressed and heated until they fuse into a single block with the material ’ s original strength and characteristics . These heat exchanger technologies have been in use for a long time and have been refined over the years . PCHE heat exchangers , for example , whilst being comparatively ‘ new ’ have been in production for approximately 40 years . Certification standards , processes and data on durability are therefore well defined , providing strong data on performance , design life , reliability , and servicing requirements . Manufacturing time and cost for many of these solutions may be high , leveraging bespoke machinery with high tooling costs . They may be comparatively bulky and heavy for mobile or space-constrained applications .
AM in energy heat exchangers Driven by the need to be more efficient and developing more sustainable practices , energy companies are fast exploring the benefits and solutions offered by AM technology and understanding both the challenges and opportunities this technology can offer in its current and near-future state .
Benefits of AM The core benefit that AM offers is the capability to intensify the heat transfer process and provide new approaches to maintenance processes . New freedoms of design , bespoke packaging and the opportunity to leverage novel materials and processes are delivering higher performance and lower pressure drop , also enabling reduced volume , size and weight . Monolithic parts and the promise of distributed manufacturing drive potential reductions in operational expenditure associated with large assets and lower supply chain and supplier risks . Performance – the ability to design a wildly different and “ exotic ” core geometry that is free from the constraints of traditional tooling means the core geometry can create a more effective transfer of heat for a given set of fluids . Small scale fins and turbulators can be printed as inherent elements of the channels reduce unwanted fluid boundary layers whilst optimizing pressure drop 1 . With accurate simulation of the fluid properties , the geometry of a given core can be varied to suit the specific boundary conditions of the application , and even vary within the core to optimize for the changing properties of the fluids being cooled . Multiple fluids can be incorporated into a single core with comparative ease , further increasing efficiency within a system . Bespoke dimensions and packaging – AM also provides improved freedoms regarding the overall dimensions and shape of a heat exchanger . A heat exchanger can be contoured to accommodate other system components , space constraints or can be developed as cartridges or inserts to fit into traditionally manufactured housings . Radical shapes also come with very minimal impact on the end cost of the item , although performance may be impacted . Light weight , reduced volumes , reduced size – highly efficient heat exchange implicitly results in less bulk , weight , and material use . Entire heat transfer loops may be removed from processes where significant efficiencies in constrained volumes or multi-fluid heat exchangers can be employed . Monolithic parts – a single part may be produced with a single input material reducing the BOM . This has the potential to reduce or remove inherent failure points at joins , although the manufacturing process also requires careful control of calibration , parameters , and design to avoid other challenges . www . heat-exchanger-world . com Heat Exchanger World September 2022
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