Embed Size (px)
Citation preview
Ultra Performance Heat Exchanger Enabled
by Additive Technology (UPHEAT)Dr. Lana Osusky, GE Research
We are leveraging the design flexibility of additive manufacturing and using a new
DMLM superalloy to enhance the state of the art in both heat exchanger design and
additive manufacturing capability.
High Intensity Thermal Exchange through Materials and Manufacturing Processes (HITEMMP)
Annual Program Review – October 21-22
UPHEAT Project OverviewFed. funding: $2.5M
Length 30 mo.
Team member Location Role in project
GE Research Niskayuna, NY Program Lead, Alloy Research, Design lead
University of Maryland College Park, MD Design System development, CFD, FEA analysis
Oak Ridge National Lab Oak Ridge, TN Corrosion Science
Context
Additive design & manufacturing expertise
Gerstler, William D., and Daniel Erno. "Introduction of an additively manufactured multi-furcating heat exchanger." In Thermal
and Thermomechanical Phenomena in Electronic Systems (ITherm), 2017 16th IEEE Intersociety Conference on, pp. 624-633.
IEEE, 2017
Superalloy design for DMLM NGHX heat exchanger design & optimization methods Corrosion Science
Heat Exchanger Design Details
2
Hot side temperature capability @ 40khrs
Mass Power Density
Volume Power density
UPHEATState of the art
900°C600°C
3.76 kW/kg1.6 kW/kg
10836 kW/m3
2000 kW/m3
3D trifurcating core + central manifolds yield state-of-the-art temperature capability & power density for full HX design
Heat Exchanger Design System
3
Unique GE design tools + commercial CFD/FEA software incorporated into design system frameworkReduce lead times by distilling UPHEAT data into reliable screening correlations for preliminary design
HT Screening
Equations
Mechanical Screening
Equations
CAD
ModelOptimization
HT & Mech
Multi-scale Modeling
Design
requirements
Performance
Test
Preliminary Design (est. 2 wks)
Detailed Design
(est. 6-8 wks)
M5.1
Cost ModelM6.2
M1.3
Build
Post process &
leak check
M3.1
M4.1
Crack risk
screeningM3.1
M1.2
▸Time dependency: Steady State
▸Energy: ON
▸Turbulence: k-ε Turbulence model
▸Fluid Properties: Temperature dependent
▸Boundary Conditions:– Top & Bottom faces: Wall BC
– Mass flow inlets
– Pressure outlets
▸Scheme: Coupled PV scheme
▸Discretization: Second order upwind
▸Convergence Criteria: – 1e-3 for turbulence parameters
– 1e-6 for others
CFD Modeling
4
CFD Validation & Test Capability
5
CFD design model predicts heat transfer & pressure drop to within 10% of experimental dataTeam is planning full-scale HX test with high temperature air and sCO2 by Q10
▸Leveraging UMD design & optimization expertise with GE experimental capabilities
GE Heat Exchanger Test Lab 144kW 900°C air capability
GE Sub-Scale HX Test Lab 1.5kW 30°C capability
Material Updates‣ Material: AM303 – Ni-based superalloy designed for DMLM
‣ Have progressed from trial prints to subscale heat exchanger builds, planning for full HX build/test by Jan ‘22
6
Temperature
Stre
ss
Creep model, calibrated through AM303 testing up to 1500hrs, shows margin against UPHEAT targets. Thin-wall debits to be defined on program.
AM303 similar to commercial alumina-forming alloys. Improved performance over chromia-forming alloys at 900°C.
Bulk Creep Capability Corrosion
1400F 1650F
Material Updates‣ AM303 Properties
7Insert Presentation NameOctober 29, 2020
AM303
René 108Casting
DMLMAM303
DM
LMA
M3
03
Tensile
Fatigue @ 870°C(1600°F)
Manufacturing Process Development Updates‣ Additive manufacturing with Direct Metal
Laser Melting (DMLM) on in-house machine
– Recoater spreads thin layer of metal powder on print bed
– Laser follows software-controlled scan path to melt the metal particles to create 1-layer object cross-section
– Repeat for next process layer
– After all layers printed, excess unmelted powder is brushed, blown or blasted away
‣ Manufacturing Process:
DMLM build ➔ Post Processing HT & HIP
8
In-house DMLM machine allows faster turn-around of build trials and prototypes
Manufacturing Process Development Updates‣ Team has leveraged in-house design tools and additive manufacturing expertise to navigate early build
challenges
9
From failed build to multiple printed subscale heat exchangers in 3 weeksTeam has successfully met critical thin wall manufacturing milestone
Manufacturing Process Development Updates‣ Post processing heat treatment and Microstructure
10Insert Presentation NameOctober 29, 2020
• Transverse grain size: ~ 120 µm (thick part)
• Transverse Grain Size: ~100 µm (< 1 mm wall)
• Aspect Ratio: 2.0
• Heat treatment did not fully eliminate texture
Technology-to-Market Updates‣ Strong partnership between GE Research & GE Additive to drive
commercialization strategy
‣ Customer relationships through product-driven research for GE Aviation & GE Gas Power
‣ GE Additive proprietary cost model
‣ Preliminary market screenings show pull from aviation, power, processing markets
– High temperature capability efficiency improvements
– Power density size & weight reductions
‣ Key assumption: material & manufacturing cost estimates for commercial production are reasonably close to our estimates such that target of <6000 $°C/kW can be achieved
11
Like
liho
od
Almost Certain
Likely
Moderate
Unlikely
Rare
Insignificant Minor Moderate Major Catastrophic
Consequences
Risk Update
Please list the primary risks to your project’s success that were identified then at the beginning of the project, and how your past year’s efforts have changed these risks.
Risk #
Thin wall manufacturing 1
Simulation file sizes/computational time
2
1
2 1
X
X
Now
Start of project
2
Progress Against Tasks – Timetable
13
Thin wall manufacturing
(GE)
Corrosion screening
(ORNL)
Subscale heat transfer &
pressure drop experiments
(GE)
Design modeling system
(UMD)
Full scale HX design & test
(GE)
Final corrosion science report on new alloy
(ORNL)
Design optimization
system
(UMD)
Q6
Design 1
Go/No-Go
Q10Final Design
ReviewQ1-Q5
Q6-Q10
Potential Partnerships▸Team must continue to mitigate thin wall
manufacturing risk as designs scale to larger size & complexity - exploring additional internal / external funding options to support
▸Team is well-positioned to commercializetechnology through partnerships with GE Additive and customers within and outside of GE across multiple markets
▸Beyond the HX, development of new material may present additional opportunities to partner for other applications
14Insert Presentation NameOctober 29, 2020
