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Copyright © TWI Ltd 2018
Friction Stir Channelling: A leaner method of manufacturing heat
exchangers for aerospace
Joao Gandra
Advanced Engineering Show
1st November 2018
Copyright © TWI Ltd 2018
Overview
▪ Aircraft thermal management
▪ Friction Stir Channelling
▪ Initial concepts
▪ TWI’s invention
▪ Technology demonstrators
▪ Potential applications in aerospace
Copyright © TWI Ltd 2018
Aircraft of the future
Airbus 2050 concept plane. Airbus
“Boeing is back in the wind tunnel testing (…) the Blended Wing Body”
Boeing press, Sep 2016
“Airbus Zephyr Solar (…) flies for longer than any other
aircraft during its successful maiden flight”
Airbus press, Aug 2018
“Airbus, Rolls-Royce, and Siemens team up for electric future. Partnership launches E-Fan
X hybrid-electric flight demonstrator”Airbus press, Jul 2018
“NASA Awards Contract to Build Quieter SupersonicAircraft, Lockheed Martin X-59 QueSST”
Nasa press, Apr 2018
“First BelugaXL becomes airborne for its maiden flight”
Airbus press, Jul 2018
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Aircraft thermal management
What’s the common trend?
▪ Increasing incorporation of electronic systems
▪ Higher demands for engine performance and efficiency
▪ Increasing use of composite structures (sensitive to heat)
Dissipation of heat from:
▪ Engines
▪ Hydraulics
▪ Electronics
Re-distribution for anti-icing on:
▪ Wings
▪ Engine cowlings
▪ Tail flight control surfaces
Demand for compact, lightweight and efficient
heat transfer solutions
Improved thermal management
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Friction Stir Welding
▪ A rotating FSW tool is plunged between two clamped plates, plasticizing the material
▪ The rotating tool is then traversed forming a solid-phase joint
Aluminium alloy
6mm thick plate
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FSW applications
Used worldwide for a range of demanding applications, including safety critical transport
structures and consumer electronics
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FSW in thermal engineering
(1) Heat exchangers by Nippon Light Metal
(2) Heat sinks for ABB Semiconductors
(3) Water cooled engine block
(4) Panel for pre-pressing of fish blocks before quick freezing
(2)(1)
(3) (4)
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TWI inventionFriction Stir Channelling
Sub-surface machining technology for metallic components
Networks can be incorporated inside plates or tubular structures for fluid flow
UK and PCT patent pending
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AA1050-H15 plate, 20mm
TWI inventionFriction Stir Channelling
Sub-surface machining technology for metallic components
Networks can be incorporated inside plates or tubular structures for fluid flow
UK and PCT patent pending
Copyright © TWI Ltd 2018
Demonstrators
Cool plate AA1050-H14 (20mm thick)
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Demonstrators
Cool plate AA1050-H14 (20mm thick)
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Demonstrators
Cool plate AA1050-H14 (20mm thick)
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Demonstrators
Cool plate AA6082-T6 (15mm thick)
Cross section by X-ray CT
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Demonstrators
Cool plate AA6082-T6 (15mm thick)
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Demonstrators
Cool plate AA6082-T6 (15mm thick)
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Demonstrators
Cool plate AA6082-T6 (15mm thick)
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▪ Heat dissipation devices
▪ Anti-icing systems
▪ Networks for lubrication or hydraulics
▪ Embedded instrumentation (structural health monitoring or communication)
▪ Reducing heat signature
Potential applications in aerospace
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Potential applications in aerospace
Engine cooling
Opportunity:
Incorporation of FSC cooling networks in nacelles
▪ Heat exchangers cool oil using air or fuel
▪ Located between the engine and the nacelle
▪ Disruption to airflow, creating drag and decreasing thrust output
Courtesy of Safran Aero
Boostershttps://www.safran-aero-
boosters.com/media/20151222_enhanced-heat-exchanger-skills
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Potential applications in aerospace
▪ Heat exchangers are installed under the wing surface to cool hydraulic fluid
Hydraulic systems cooling
Opportunity: FSC could offer integrated manifolds replacing hoses, pipes and fittings
Boeing 737 hydraulic case drain
fluid heat exchanger installed in
the fuel tankhttp://www.flight-mechanic.com/large-aircraft-hydraulic-systems-boeing-737-next-generation-hydraulic-system/
Copyright © TWI Ltd 201820
▪ Heat exchangers (plate, block or helical-coil)
New design possibilities
Potential applications
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▪ Cooling channels in the wall of chambers etc. in wafer fab / processing equipment
Courtesy of Kurt J. Lesker Companyhttps://www.lesker.com/newweb/manufacturing/hydracool.cfm
Potential applications
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Next stagesTechnology Readiness Level
1st
Exploratory Completed 2016
JIP + CRPPlanned 20192nd
Exploratory Completed 2018
SCPAvailable upon consultation
Copyright © TWI Ltd 2018
Contact
Joao Gandra
Senior Project Leader
Friction and Forge ProcessesTWI Ltd
Tel: +44 (0)1223 94 0248
E-mail: [email protected]
Web: www.twi-global.com
