Impact of additive manufacturing on internal cooling channels with varying diameters and build directions

Alexander J. Wildgoose, Karen A. Thole, Paul Sanders, Lieke Wang

Research output: Chapter in Book/Report/Conference proceedingConference contribution

4 Scopus citations

Abstract

The use of additive manufacturing (AM) processes, such as direct metal laser sintering, provides the design freedom required to incorporate complex cooling schemes in gas turbine components. Additively manufactured turbine components have a range of cooling feature sizes and, because of the inherent three-dimensionality, a wide range of build angles. Previous studies have shown that AM build directions influence internal channel surface roughness that, in turn, augment heat transfer and pressure loss. This study investigates the impact of additive manufacturing on channel feature size and build direction relative to tolerance, surface roughness, pressure losses, and convective cooling. Multiple AM coupons were built from Inconel 718 consisting of channels with different diameters and a variety of build directions. An experimental rig was used to measure pressure drop to calculate friction factor and was used to impose a constant surface temperature boundary condition to collect Nusselt number over a range of Reynolds numbers. Significant variations in surface roughness and geometric deviations from the design intent were observed for distinct build directions and channel sizes. These differences led to notable impacts in friction factor and Nusselt number augmentations, which were a strong function of build angle.

Original languageEnglish (US)
Title of host publicationHeat Transfer
PublisherAmerican Society of Mechanical Engineers (ASME)
ISBN (Electronic)9780791884164
DOIs
StatePublished - 2020
EventASME Turbo Expo 2020: Turbomachinery Technical Conference and Exposition, GT 2020 - Virtual, Online
Duration: Sep 21 2020Sep 25 2020

Publication series

NameProceedings of the ASME Turbo Expo
Volume7A-2020

Conference

ConferenceASME Turbo Expo 2020: Turbomachinery Technical Conference and Exposition, GT 2020
CityVirtual, Online
Period9/21/209/25/20

All Science Journal Classification (ASJC) codes

  • Engineering(all)

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