Highly Compact Metallic Heat
Exchangers for Extreme
Environments (EEHX)
Dr. Ali Yousefiani
Boeing Research & Technology
Develop heat exchangers for use
in long-life sCO2 Brayton power
cycles, which can be employed in
high efficiency Integrated Power
& Thermal Management Systems
(IPTMS) for hypersonic aircraft
Project Vision
Project Overview
Historical Context:‣ BR&T has been developing EEHX (~800C) since 2008. Long history of development of performance enhanced
metallics using advanced bottom-up synthesis and manufacturing approaches. Subawardee on ARPA-E METALS
‣ UMD is world leader in broad HEX technology. UMD has been collaborating with BR&T on development of AM
aircraft engine precoolers (>500C) under ARPA-E ARID
‣ ATI is a global manufacturer of technically advanced specialty materials and complex components
‣ Metalysis has developed a unique technology (originally based on the Cambridge FFC® process) capable of
producing a vast range of metals and complex alloy powder feedstock at low cost
‣ AFRL is a world leader in refractory complex concentrated alloy development and characterization
Fed. funding: $2.4M
Length 30 mo.
Team member Location Role in project
Boeing Research & Technology (BR&T) CAManage program and lead materials, manufacturing processes and
EEHX development; T2M planning & TEA for aerospace market
University of Maryland (UMD) MD Lead topology optimization, EEHX testing, T2M for power generation
ATI NC Lead traditional feedstock production/characterization and AM tasks
Metalysis UK Lead nontraditional feedstock production/characterization
Air Force Research Laboratory (AFRL) OH Lead alloy selection and support development/characterization
1
Innovation, Objectives, Final Deliverable
2
Advanced Manufacturing: AM, PM, Hybrid AM-PM, SPF, and Novel Solid State Joining
Heat Transfer Flow Distribution
Advanced EEHX Design & Multi-Disciplinary Topological Optimization (MDTO)
Advanced Extreme Environment
Enhanced Superalloy and Complex
Concentrated Alloy Systems
AM
PM
FEM
BR&T Highly
Compact EEHX
• Builds on recent EEHX successes on ARPA-E &
DARPA funded programs (up to 800°C and 20 bar)
• Multi-disciplinary topologically optimized design
for long life (MTBF>40,000 hours) and efficient (ε >
82%) operationo Near-Term Market Entry 800C EEHX
o Advanced Topology Optimized 1000C EEHX
• Novel complex concentrated alloy systems that
will offer superior extreme environmental
durability and thermal/structural performance
supporting > 1000°C long term operation
• Hybrid combinations of additive/subtractive
fabrication, powder metallurgy processing,
advanced forming, and solid state joining to
address cost and manufacturability risks
BR&T’s Highly Compact and Tunable
Advanced EEHX Enables Next Generation
Power Systems with Ultra-High Efficiency
BR&T Highly Compact Extreme Environment Heat Exchanger
‣ Design
– Variable fins manifold-microchannel and primary surface heat exchanger configurations
– Low pressure drop due to improvements in flow distribution using manifolds
– Topology optimization will be used to improve EEHX power density
– Design for manufacturability is a key consideration
‣ Material
– Enhanced Superalloys – TRL5
– Extreme Environment Complex Concentrated Alloys –TRL2
‣ Manufacturing Process
– Hybrid combinations of additive and subtractive manufacturing, powder metallurgy, advanced forming, and solid state bonding
– Broad maturity range (TRL4 – TRL9)
3
Conventional
Design Topology Optimized
Design
Task Outline
4
Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10
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EHX
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EHX
Perform Manufacturing & Processing Trails, Test,
Evaluate, and Downselect
Alloy for 800C EEHX
Perform Manufacturing & Processing Trails, Test,
Evaluate, and Downselect
Alloy for 1000C EEHX
Define 800C
Material System Options
Produce Feedstock for 800C Alloy-1
Build AM Based 800C EEHX Coupons
Test/Evaluate 800C EEHX
Coupons and Select
Optimum Fabrication Approach
Produce Feedstock for 800C Alloy-2
Build Hybrid 800C EEHX Coupons
Produce Feedstock for 1000C Alloy-1
Build AM Based 1000C EEHX
Coupons
Produce Feedstock for 1000C Alloy-2
Build Hybrid 1000C EEHX
Coupons
Build, Test, & Evaluate Near-
Term Market Entry Prototype 800C
EEHX
Build, Test, & Evaluate Advanced
Topology Optimized
Prototype 1000C EEHX
Test/Evaluate 1000C EEHX
Coupons and Select
Optimum Fabrication Approach
Feedstock Selection, Production, Test, & Evaluation Manufacturing Process Selection EEHX Production, Test, & Evaluation
Feedstock Selection, Production, Test & Evaluation Manufacturing Process Selection EEHX Production, Test, & Evaluation
MDTO Tool Development and Prelim Design
Coupon Design and MDTO Model Validation
Detailed EEHX Coupon and Prototype Design
Prelim EEHX Design & Analysis for IPTMS
Define 1000C
Material System Options
Go/No-Go 2 Go/No-Go 3Go/No-Go 1
Anticipated Challenges and Potential Partnerships
5
