添加剂制造紧凑板式换热器的最优尺寸和材料选择
Optimal Sizing and Material Choice for Additively Manufactured Compact Plate Heat Exchangers
AI总结：
本研究探讨了添加剂制造对紧凑板式换热器尺寸和材料选择的影响，发现塑料在多数情况下表现优于铜等金属。
摘要：
添加剂制造（AM）的进步为通过利用灵活的几何形状来设计紧凑换热器（cHEXs）提供了新的机会，以提高能量和材料效率。然而，众所周知，在逆流cHEXs中减少尺寸会由于固体材料中的轴向热传导而降低效果，这强烈依赖于材料热导率和壁厚。理解基本热传递机制与制造约束之间的相互作用对于设计下一代能够充分利用AM形状灵活性的紧凑热系统至关重要。本研究探讨了材料选择和AM薄壁限制如何影响紧凑板式换热器中可实现的最大功率密度。一个优化框架在固定的压降和有效性条件下评估了六种材料，包括塑料、奥氏体钢、Al2O3、AlN、铝和铜，同时考虑了AM特定的厚度限制和最小板间距以应对结垢风险。结果表明，尽管铜具有最高的热导率，但铜始终产生最低的功率密度，而塑料在大多数优化场景中实现了最高的功率密度。在没有制造或结垢限制的情况下，塑料在大多数优化场景中实现了最高的功率密度。在没有制造或结垢限制的情况下，塑料在大多数优化场景中实现了最高的功率密度。在均匀板厚或结垢限制的情况下，性能差距缩小，使塑料和奥氏体钢变得可比。当应用材料特定的厚度限制时，塑料再次在紧凑性方面领先，由于其优越的薄壁可制造性。这些发现强调了AM约束对cHEX紧凑性的影响，并指出低导热材料可以比铜等金属在高密度换热器设计中表现更佳。
英文摘要：
Advances in additive manufacturing (AM) enable new opportunities to design compact heat exchangers (cHEXs) by leveraging flexible geometries to improve energy and material efficiency. However, it is well known that reducing size in counterflow cHEXs can degrade effectiveness due to axial heat conduction through the solid material, which depends strongly on material thermal conductivity and wall thickness. Understanding the interaction between fundamental heat transfer mechanisms and manufacturing constraints is essential for designing next generation compact thermal systems that fully exploit AM's shaping flexibility. This study investigates how material selection and AM thin wall limitations influence the maximum achievable power density in compact plate heat exchangers. An optimization framework evaluates six materials including plastic, austenitic steel, Al2O3, AlN, aluminum, and copper under fixed pressure drop and effectiveness, while accounting for AM specific thickness constraints and a minimum plate spacing to address fouling risks. Results show that copper consistently yields the lowest power density despite having the highest thermal conductivity, whereas plastic achieves the highest power density across most optimization scenarios. Without manufacturing or fouling constraints, plastic outperforms the baseline steel design by nearly three orders of magnitude. With uniform plate thickness or fouling constraints, the performance gap narrows, making plastic and austenitic steel comparable. When material specific thickness limits are applied, plastic again leads in compactness due to its superior thin wall manufacturability. These findings highlight that AM constraints strongly affect cHEX compactness and that lower conductivity materials can outperform metals such as copper in power dense heat exchanger designs.
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