3D Printed Heat Exchanger Uses Gyroids for Better Cooling | The Cool Parts Show #43
Вставка
- Опубліковано 30 вер 2024
- Advanced Engineering Solutions applied geometry that could only be made through additive manufacturing to the redesign of a heat exchanger for the gearbox oil of a helicopter. The result: four times the cooling in a heat exchanger one half the size of the original. Gyroid lattices inside this heat exchanger maximize inner surface area to achieve the more effective heat transfer. This part was one of the audience-selected winners of our first-ever contest, The Cool Parts Showcase.
This episode brought to you by Carpenter Additive. www.carpentera...
LEARN MORE ABOUT:
- Advanced Engineering Solutions: www.aes.nu/
- The Cool Parts Showcase winners: www.additivema...
- Another cool part using gyroids, quantum physics vacuum chamber: www.additivema...
- Laser powder bed fusion: www.additivema...
- EOS: www.eos.info/en
- Additive Works Amphyon for Creo: additive.works...
* * *
Subscribe to THE BUILDUP, Additive Manufacturing Media's newsletter on 3D printing for industrial production: gbm.media/Join...
Thank you everyone for watching!
This part was a winner of The Cool Parts Showcase. A viewer below asked about other winners. Here are the other winning entries:
www.additivemanufacturing.media/articles/3d-printed-metal-component-for-cnc-machining-center-the-cool-parts-show-47
www.additivemanufacturing.media/articles/custom-canine-wheelchair-from-carbon-fiber-reinforced-pp-the-cool-parts-show-44
(Want to see the entire field of competition? Here are all the finalists: ua-cam.com/video/SY2RDQFxrW0/v-deo.html)
I'm starting to see a pattern with this form of manufacturing, cooling, engine pistons to monolithic suppressors. It's really cool stuff.
You could tell how excited Andreas was that technology had finally reached a turning point where he could not only model these really interesting and potentially applicable mathematical theories, but he could also have them manufactured. It's always nice to see guys who are experts on the theory, only because the technology didn't exist to realize it, end up living until the technology becomes available and accessible.
That lady is a great presenter! nicely done
Interesting. Will be even more interesting and practical for the client to see what the pros and cons are and mitigating the cons to make an equivalent AND better than 3D printed product.
what propably didnt get mentioned, at least i didnt recall it, is that its also a much more reliable part since its made from essentially one piece, there is little to go wrong.
From a nuclear engineering perspective this is really interesting. When you're making 3,000,000,000 W of heat per core, heat exchangers are no joke. The main advantage I'm seeing for me is It being one continuous homogeneous material with a well supported interior and obviously the efficiency. Heat exchangers die from the tubes rattling against them selves and anything near them. I wonder if something similar could be made out of a material that can handle the temperatures, pressures and corrosive conditions. I don't hardly ever work with 3d printers so I'm not sure what is realistically possible.
This particular type of additive manufacturing (or "3D printing") uses a laser to melt a metal powder in a precise pattern. It is no coincidence that the metal used has a relatively low melting point.
@@brianb-p6586 just that you are aware: there are completely 3d-printed Rocket Engines on operational Rockets that got to Orbit. Namely the Rutherford Engine on Rocketlabs Electron. I couldnt find much data about the Chamber Pressure and Temperature, but i am sure it is higher than the use case of the initial commenter.
wow now that some awesome tech!
It's neat. But the old design it replaces seems serviceable in how it could separate into two major components. With the gyroid exchanger you'd better ensure that the fluids going through it don't have any contaminates, because it can't come apart for cleaning let alone having any luck fitting a brush through those complex passages. If something fouls it, you're SOL short of a complete replacement. Sometimes those things matter in an application despite how genius something like this may seem.
Heat exchanges are used everywhere in industry and ones 4 times more efficient is a big deal.
Awesome. How do you clean it when fouling accumulates?
Would have been cool to have a cut open sample, the unsteady camerawork makes it difficult to see what's going on inside
Slavoj Zizek engineer isnt real.
Him:
In regards to simulated fluid flow. I'd be curious of the oil pressure delta if any from the current to proposed design. With smaller passageways compared to the current design, I imagine you either need to run higher head pressure or it results in lower overall oil pressure. Just a single curiosity I have, seems like a genius part.
The passageways account for 50% of the cross sectional area of the heat exchange and constructively interfere. It likely has improved flow rate over a similarly sized traditional heat exchanger
Interesting seeing you here ha ha
Response from Dr. Andreas Vlahinos: “The pressure drop on tube and shell designs is higher since the fluid needs to travel through a single tube. Gyroids provide several passages and therefore have better pressure-drop performance. Using optimization, within the CAD environment, one can use the unit cell sizes (dx, dy, dz) and the gyroid thickness (t) as design variables to minimize pressure drop and keep temperature less than the requirement. I demonstrate this workflow in my short courses and university classes.”
@@darkfur18 I was thinking this may be the case
Nice! Good to see 3D printing enter the heat exchanger market. Heat exchangers have lots of internal geometry so are a perfect fit.
The first time I saw a gyroyd infill, I thought it would make a great intercooler core for turbocharged applications
What a passionate man Andreas is! Happy for him using gyroids in a real life product =)
See now this is one of the real applications for additive manufacturing. Not dumb crap like 3d printing entire cars and houses.
well, better designed parts could take advantage of additive to reduce weight and complexity in cars, or increase performance, like the suspension joints or engine internals, while possibly reducing costs. the Dreamliner plane is using 3d printed titanium for it's engine pylons as it ended up reducing costs and waste compared to billet titanium
Well perhaps we could build strange surfaces for houses too 😅
@@l3d-3dmaker58 This is only on the condition that these parts are just as easy to maintain and control the quality of production, as well as the possibility of repair, production by simple means.
This isn't actually a worthwhile application of 3D printing yet. The metalurgy of 3D printed parts is still trash, and that doesn't seem to be changing very quickly. Also, the hidden internal passageways SEEM like a neat benefit, until you realize that it cannot be inspected prior to deployment or as part of routine maintenance. On top of that, the parts still require finish machining for threads and precision surfaces, which negates half of the benefits. Ultimately, these kinds of parts can not currently pass any level of the rigorous scrutiny that they must in order to become an FAA certified component.
Cool designer, he has the passion that many half his age don't have.
It helps to work on something interesting and not just trying to manufacture a thing for as cheap as possible.
The augmented reality flow simulation is amazing. Talking about parts count reduction, that also means, if additive is reliable enough, a lesser probability of failure because there no joints to fail. When you deal with the blood of the helicopter that's quite important too.
The main thing is the hype on modern complex technologies and ideas. No one cares how it will be serviced, checked, cost and production time.
@@VictorLarsen-fy9ls Well there is no servicing this exchanger, and production times for 3d metal printing are coming down so production time and cost are steadily coming down. Honestly 3d printing works great for prototyping and testing new designs on the fly but I'm not sure if it will ever translate to mass production on a cost basis.
@@timtrainque1060 I think at least for air transport they will not make any important details like this, using 3D printing technology. You can get good single copies, spend a lot of time refining the surface, checking, testing. But all the same, it's not really worth it and the weight gain is not significant there. For example, when an old aircraft is upgraded with new electronics, it sometimes gets tens and hundreds of kilograms in weight gain, and this is a side effect of modernization. To get the same weight gain due to 3D printing, you need to change a lot of parts, and they will be of dubious strength, these are already big risks and it's not worth it.
@@timtrainque1060 If this part ever actually gets used, it will have to be 3D printed. There are no other currently existing technologies to create these geometries other than additive manufacturing.
That being said, I'm not so concerned about servicing this part. This component is small, has negligible sources of wear (uneven heating/cooling is the only thing I can think of), and is inside an engine, where if you are taking the part out it's cause you're already replacing it, or it was in the way of something you were replacing.
@@VictorLarsen-fy9ls re: "The main thing is the hype on modern complex technologies and ideas. No one cares how it will be serviced, checked, cost and production time." indeed, for those knowing what to look for the EGO PROBLEM is real easy to spot regarding the "disconnect" that regularly happens in these situations, for like the wise technician said to the engineer "if only the people DESIGNING this stuff had to USE it and WORK on it."
I make heat exchangers at the job I work and this would be awesome to see if they would be interested in this.
The leaps and bounds of materials and process leave me speechless . I have seen things that even my sci-fi reading 15 year old mind never imagined .
this is probably the biggest win for this generation of additive. I worked in a lab and we were doing a bunch of heat exchangers as well.
really curious about fouling and how you'd clean the internals of a unit like this. we deal with tube and shell exchangers, and the maintenance on those are needed fairly often, so I'm curious what the trade off is in a design like this.
We put that question to Dr. Vlahinos. He said, “The AM-generated surface roughness provides a higher coefficient of heat transfer. We have not done any testing on fouling. We expect fouling not to be significant as gyroid-flow-domain paths are smooth and we don’t have flow particles hitting flat surfaces or internal cavities. I agree that research needs to be done for various fluids to assess the impact of fouling on gyroid heat exchangers.”
@@AdditiveManufacturing That is an enormous red flag, quite honestly. Any part that cannot be inspected cannot be trusted.
Maybe you just run it at a high head pressure with some alcohol or something?
I should imagine a sonic cleaning after "fouling" would do. What temp. drop/increase can this device achive.?
Cool part.
If it can withstand the vibrations from the helicopter, then that seems like a wise part to be implemented.
Aluminum alloy, should hold up well
This is one of those things that brings us closer to our real technology looking like advanced alien tech... It's so brilliant.
Literally game changing.
I am an engineer and worked around engines a lot, the design reminds me to the common heat exchanger on cars, but the manufacturing process go me thinking. First the tensile strenght. One of the common materials used in heat exchangers is duplex 2205 stainless steel, witch is manufactured by forging, and so achieving the required molecular structure and a smooth surface. Then it is built in into the heat exchanger. The tensile strenght of the Duplexx 2205 is 90ksi compared to AlSiMg witch is around 33ksi. The rough surface finish is something that is commonly not desireable in contact with fluids, witch means higher pressure especially early when the fluids are cold. Is there a technology avaibe witch allows similar structures, but with smoother finish and with a higher tensile strenght as the mentioned AlSiMg?
It could probably be subjected to an "Extruded Hone" process to smooth the surfaces.
smoother finish --> extrude hone after printing :) higher tensile strength --> yes, you probably can't get the work hardened molecular structure, but you can even print inconel!
I don't think a smoother surface finish can be achieved, but I know that the powder prints can be made with some steel alloys. I know those technologies are also used in (extremely high performance) rocket engines, it may be interesting to look there on how they are dealing with those problems.
It's possible to heat-treat the surface, but it may lead to deformations.
Perhaps 3d printing a hollow ceramic negative and casting the part in a vacuum? then for the surface finish, you could pump a suspension of shot through it to shatter the ceramic and peen the exposed metal surfaces.
It's a good showcase of the application of the concept in reality.
Oh my God it's beautiful. I want this for an intercooler.
That’s a thing of beauty.
Alternatively... the outer lattice structure not only supports the structure, but passively allows for some better heat exchange to surrounding air.
I never suspected I could fall in love with a heat exchanger.
A heat exchanger demands no fluid contamination on either channel. With laser sintering the finished part is soaked in the bonding metal dust & there is no guaranteed way to dislodge and remove all of it. A solution might be to bring the completed part up to high temperature, just below melting point, then blasting through very hot gasses through each port in sequence. The idea here is to "glaze" the internal surfaces and melt any remaining particles. Destructive testing is needed to find the sweet-spot for this theoretical process.
I was thinking about this while watching. I believe ultrasonic cleaning and blasting liquids through it for a short period of time would probably clean it up fine.
Whats missing is incorporating the mounting points.
So smart! I love 3D Printing!
I'm imagining one of these falling through a time warp back to the 1950's and engineers taking it apart and asking "How on earth did they make this thing?"
fine casting
Depending on the thermal conductivity of the material the outer ribs could also contribute to the heat dissipation due to greater surface area, paired with titanium oxide based paints I could imagine the thermal dissipation seeing reasonable improvements.
more surface area the better
Or they could have printed fins around it, like the fins used to cool a motorcycle engine.. either way the fins can be cooled with air passing through it or liquid like a radiator would
Actually, no. They idea behind this is that heat is removed from liquid oil by liquid fuel, and then this hot fuel goes to the engine. This heat exchanger is placed inside of a helicopter, so it can't radiate heat because it will heat up INSIDES of a helicopter.
Not just self-supporting, but the continuous wriggling of the gyroids accelerates the fluids side to side, causing local hot and cold volumes to convect and mix. That forces mixing and turbulence at the wall and prevents stratification in the fluid. Brilliant!
I want one! To me, it's a work of art!
You earned a new sub today. That heat exchanger is the bomb! I hope to be able to buy one for water cooling but made out of copper for PC enthusiasts.
Always hilarious to see random youtube commenters suggest that the industrial design award winners should think about X,Y or Z.
Do they seriously believe they've got a better handle on the situation & that the group behind this didn't consider the required durability & servicing requirements for the application, or the testing procedures?
I have my doubts that this is a real product that will ever be put on a military aircraft. I think this is a device manufactured to promote their technical capabilities more than a heat exchanger that will ever get near to an actual helo engine. It is quoted above that they gave NO consideration to the possibility of fouling/blockage. If that isn't a red flag to you, it oughta be.
@@chuckschillingvideos Could you give me the timestamp of when they stated that they ignored fouling/blockage considerations? It's not popping on the transcript.
The external rib idea is interesting. I'll try that on my own hobby prints
I'm not sure why they made a big deal of it, car parts have used them for decades. Recent plastic intake manifolds in particular.
@@hydrocarbon82 I was thinking the same thing... Almost all the parts in automotive industry (and others) have that. This is way older then additive manufacturing boom
It's just a heat sink. Ain't nothing revolutionary about heat sinks - they've been in use in a wide variety of applications for decades and decades.
It's super common on rocket fuselages, just on the inside instead of the outside. I'm sure there are sources that talk about the inside of SLS and Falcon somewhere, they would probably be the state of the art right now in that area.
I would have been very impressed if you'd actually tested the thing and shown ACTUAL PERFORMANCE DATA.
Hi, absolutely fascinating topic 👍. My mind is working overtime with the possibilities. One point you didn’t cover was a comparative costing between new and old build processes and time to build/assemble the unit.
Isn't it amazing what the human mind can do when it's used for this kind of thinking instead of mundane things like fighting wars. Check out Elon Musk for this type of thinking in the physics/engineering world to do nothing more than build better cars.
No one mentioned the outer grid adds surface area as well !!
Incredible! Very cool application of a surface that I haven't heard about!!! I'm looking forward to learn more about 'Gyroids'. I think the heat exchanger is heat insulated in assembly phase. My best regards!
Validation on that seems like a lot of work; good work to anyone who can get that into a working helicopter.
What an excellent achievement and a strong marker that the future of design will accept 3D printing and in fact will compliment innovation.
Well, that was pretty freaking cool.
Don't really have any idea about what's being discussed, but I like that it looks like an owl. I'll take 3.
This is the kind of future I wanted when I was a kid.
Really great concept. On a different note: I love the AR app that shows the inside of the model. Do you have idea what app they were using to overlay the 3D model/animation on the part?
a free app called "View" from PTC
OMG I want to have a long ass brunch with this greek dude. I would be fascinated.
Perhaps the outer grid could be an isogrid for even more savings. Outstanding design
Imagine, printing engine or motors which you can direct fuel or other fuel flow to cool the motor, Just like how the rocket engines for NASA does. Less parts, lighter, more rigid. The possibilities are endless!
A classic plate style heat exhanger would also have been an improvement, this is like going from a wooden wheel to a carbon fiber wheel, when aluminium wheels would have been a massive improvement already.
I'd be willing to bet that this can tolerate significantly higher pressures than an equivalent-surface-area plate-fin HE. Higher pressures mean you can make the flow paths longer before losing pressure, which means a better exchanger performance. All theoretically, of course. In practice, these wall thicknesses might be pretty bad for performance.
@@avialexander An ordinary heat exchanger was made of pipes and tubes - what could be more reliable and simpler?
@Vlad they're talking about plate heat exchangers not tubes
I would love see this used in other domains as well: automotive, energy etc...
home heating/cooling heat pumps!
I agree. I think like most things that begin as military tech, it is just a mater of time and cost. I can see F1 being an early adopter. I'd love to show this off on a high end enthusiast computer build.
This component looks surprisingly symmetrical for something processing such different liquids. Intuitively, I expected the more viscous gear oil to have different optimal flow geometry than the fuel passages that are paired with it.
I suppose it depends on the flow rate of the 2 liquids.
Good point - but perhaps is such an over achiever already this just works. As the shapes are interlocked or mirrored it would be hard to adjust each for its optimal flow, so a design to the greatest need and then it still over achieves.
if they have similar conductivity, then symmetric surface area seems more important.
You can see the difference between volume through which the oil and fuel would from through at ua-cam.com/video/1qifd3yn9S0/v-deo.htmlm40s
The oil looks like it would flow through a much greater volume than the fuel, likely allowing for the difference in viscosity.
Interesting point to make. I don’t think the oil is so viscous compared to the fuel that it’s a huge difference.
Realize that the dynamic viscosity of water at 30-40F vs 212 is 5-6X .
Ever notice ? I think turbulent high speed flow I think the mass flow or energy to accelerate and pump the fluid is a significant proportion of the resistance so making the ports different sizes might not make a real difference ?
the good thing about halving the size is that you could basically have 2 redundant parts. it also probably drastically reduces the cost at scale since there's very minimal manual work.
Wow I never thought of that!
But I have been playing with gyroids as vibration dampening and the like.
Does anyone know of a way to generate separated gyroid as infill in a filament based slicer?
I was hoping to make an air heat exchanger for ventilation...
Wow what a fascinating use of 3D printing and such a genius design. Innovation like this can really help us move forward.
WOW, this is actually a really cool show about parts, the name isn't wrong! Never hit a subscribe button faster than I did a moment ago, can't wait to see you guys get a bigger audience. 16.2k subscribers for a channel with this production quality and unique content is genuinely criminal.
Side note, I was imagining an 3D printed ceramic matrix composite (as General Electric has pioneered) heat exchanger VERY similar to this just yesterday evening in the shower. My phone was in the bathroom with me... I wonder if it heard me talking to myself about the concept and then recommended me this video??
Thank you for sharing both in adequate detail but also with refreshing brevity.
Can this part withstand pressure jumps and thermal expansion / contraction? Isn't it going to clog? Has it been tested in real world?
And coolest looking mechanical owl i've seen in a while.
This advance could be useful in Aerotermia, Nuclear Fision and Fussion reactors, Rocketery, Computer Coolers(for classical and quantic ones), combustion engines, etc. We loose a lot of energy in noise and heat. We could warm air before enter to combustion chamber with the same heated, by explosion gas, for instance.
Problem is I'm not sure if it can handle the conditions a nuclear reactor (or other similar energy generation) heat exchangers need to take while also being easy to inspect and all that good stuff. Cool proof of concept, maybe someday after the technology matures.
I an a Network Engineer and I am so damn envious of how good the tools engineers have.
Impressive design and a great example for what can be done… just missing a few critical objectives
- maintainability (cleaning / repairs)
- inspection
Disposable part now just throw it away and print a new one !
@@darkone9572 Which is great when you're deployed out in the field and supply has that part on back order for more than 2 months. 3D printers for this kind of material don't seem to be fast and reliable enough to be a field-ready deployed piece of equipment (yet), and there would be high demand put upon them if more and more parts were made like this. There would still be wait times on turn over for the not only the part to be made but pass whatever NDT process is in place for safety as well.
Thus something you can break down, clean up, and get working with a wrench and some rags and elbow-grease has it's desirable aspects in many real world situations.
Toss it in an ultrasonic cleaner when doing maintenance? Air pressure leak-down test after cleaning?
Awesome video and awesome part as always!
Is there a shorter version, where the function and design are discussed in a way that isn't also a sales pitch for the tech? I would like to know about the part, it seems very interesting
It's nice to see someone passionate about there work. These are the results you get when engineers call the shots instead of MBAs.
Any other applications? Can this be used as the core of any liquid-to-liquid exchanger. I was thinking commercial/residential geothermal heat exchangers.
The part is nice, only its a knokoff of the brazed heat exchangers used for decades, and the "complicated structure" is dangerously near on the patented technology of one of the segment leaders and may lead to "legal funn" .... just saying
Am I the only one who thought that the original looked like an alcohol still shotgun dephlegmator? I'm now very curious if this could be used on a still.....
Cool device; however, it has what might actually be an enormous flaw in that it cannot be visually or x-ray inspected for cracks or blockages. One of the critical failure points of a heat exchanger is when the barrier between the different fluids is compromised. For example, in this case, should the barrier between fluids be compromised, you could have fuel diluting the lubricant in the gear housing, producing a gearbox failure (and possibly a helicopter crash as a consequence).
I'd be very interested to learn of the actual contracts they have actually signed with actual customers, particularly military customers. Personally, I would be a whole lot more confortable going with an inspectable component like the "ancient" tube and shell or gasketed plate heat exchangers.
Know what this would be perfect for? Homebrewers. If you can make it essentially disposable after a year or so of use.
I wonder how hard it would be to maintain one of those. Tube and shell is relatively easy to maintain. Would be interesting to see how long it could last efficiently.
would be super cool to have a miniature STL of this for the office shelf!
that’s so cool,
Interesting, but lots and lots of repetitions of the same exact information over and over....
Could this be use in the future in home heating and cooling solutions?
Yes. When those become much cheaper they will start to show up in many places.
that geometry seems so efficient that you could print it in plastic and it would still be better than most commercially available heat exchangers. just wow
make a better heatsink / waterblock for a cpu/gpu and gamers will burn a path to your door
This is the future I have been look for to come. Thank you to all 3d nerds out there that made this possible!
love how the tesla flow brought to 3D makes what simulates a heart. ty for your hard work to make this happen.
Add AI to the design process and this heat exchanger loses another 20% of material.
Could you guys talk about prices and cost differences? Awesome videos!
It's military, cost doesn't matter.
If you have to ask, it costs too much...
mind-boggling geometry inside that thing
wild stuff ! now heat rejection for the fuel itself will need the same treatment as the added efficiency of the heat exchanger will saturate the fuel with heat faster 🤣
μπραβο ρε Ανδρεα!
Could it not be integrated into the engine and rather than two fluid stages and a later air cooling stage, why not direct to air.
Who else clicked on this vid because they saw an owl in the thumbnail?
This is why 3d printing is the future for small shops, imagine ebing able to have countless parts within a day rather then weeks. Even in my bikeshop that I work at we have started to incorporate 3d printing to design new tools and tool holders.
Well said dear Lachlan. 😊🌎✨
Behind every amazing innovation is a Greek εβγε Αντρεα
Would be nice if this would be uploaded on thingiverse!
No sharp angles or transitions. Esp in a heat exchanger. Engineering 101.
Holy crap, you guys are nerds. -Podiatrist
Thanks a lot man!
Stephanie is such a smart (a geek) lady!
(4:00) Slavoy Zizek is an amazing designer