Numerical optimization, characterization, and experimental investigation of additively manufactured communicating microchannels

Kathryn L. Kirsch, Karen A. Thole

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

1 Citation (Scopus)

Abstract

The degree of complexity in internal cooling designs is tied to the capabilities of the manufacturing process. Additive manufacturing grants designers increased freedom while offering adequate reproducibility of micro-sized, unconventional features that can be used to cool the skin of gas turbine components. One such desirable feature can be sourced from nature; a common characteristic of natural transport systems is a network of communicating channels. In an effort to create an engineered design that utilizes the benefits of those natural systems, the current study presents wavy microchannels that were connected using branches. Two different wavelength baseline configurations were designed, then each were numerically optimized using a commercial adjointbased method. Three objective functions were posed to (1) minimize pressure loss, (2) maximize heat transfer, and (3) maximize the ratio of heat transfer to pressure loss. All baseline and optimized microchannels were manufactured using Laser Powder Bed Fusion for experimental investigation; pressure loss and heat transfer data were collected over a range of Reynolds numbers. The additive manufacturing process reproduced the desired optimized geometries faithfully. Surface roughness, however, strongly influenced the experimental results; successful replication of the intended flow and heat transfer performance was tied to the optimized design intent. Even still, certain test coupons yielded performances that correlated well with the simulation results.

Original languageEnglish (US)
Title of host publicationHeat Transfer
PublisherAmerican Society of Mechanical Engineers (ASME)
ISBN (Print)9780791851098
DOIs
StatePublished - Jan 1 2018
EventASME Turbo Expo 2018: Turbomachinery Technical Conference and Exposition, GT 2018 - Oslo, Norway
Duration: Jun 11 2018Jun 15 2018

Publication series

NameProceedings of the ASME Turbo Expo
Volume5B-2018

Other

OtherASME Turbo Expo 2018: Turbomachinery Technical Conference and Exposition, GT 2018
CountryNorway
CityOslo
Period6/11/186/15/18

Fingerprint

Microchannels
3D printers
Heat transfer
Turbine components
Gas turbines
Skin
Reynolds number
Fusion reactions
Surface roughness
Cooling
Powders
Wavelength
Geometry
Lasers

All Science Journal Classification (ASJC) codes

  • Engineering(all)

Cite this

Kirsch, K. L., & Thole, K. A. (2018). Numerical optimization, characterization, and experimental investigation of additively manufactured communicating microchannels. In Heat Transfer (Proceedings of the ASME Turbo Expo; Vol. 5B-2018). American Society of Mechanical Engineers (ASME). https://doi.org/10.1115/GT2018-75429
Kirsch, Kathryn L. ; Thole, Karen A. / Numerical optimization, characterization, and experimental investigation of additively manufactured communicating microchannels. Heat Transfer. American Society of Mechanical Engineers (ASME), 2018. (Proceedings of the ASME Turbo Expo).
@inproceedings{0d83ca0365a346fdbe09fcbbb1a05155,
title = "Numerical optimization, characterization, and experimental investigation of additively manufactured communicating microchannels",
abstract = "The degree of complexity in internal cooling designs is tied to the capabilities of the manufacturing process. Additive manufacturing grants designers increased freedom while offering adequate reproducibility of micro-sized, unconventional features that can be used to cool the skin of gas turbine components. One such desirable feature can be sourced from nature; a common characteristic of natural transport systems is a network of communicating channels. In an effort to create an engineered design that utilizes the benefits of those natural systems, the current study presents wavy microchannels that were connected using branches. Two different wavelength baseline configurations were designed, then each were numerically optimized using a commercial adjointbased method. Three objective functions were posed to (1) minimize pressure loss, (2) maximize heat transfer, and (3) maximize the ratio of heat transfer to pressure loss. All baseline and optimized microchannels were manufactured using Laser Powder Bed Fusion for experimental investigation; pressure loss and heat transfer data were collected over a range of Reynolds numbers. The additive manufacturing process reproduced the desired optimized geometries faithfully. Surface roughness, however, strongly influenced the experimental results; successful replication of the intended flow and heat transfer performance was tied to the optimized design intent. Even still, certain test coupons yielded performances that correlated well with the simulation results.",
author = "Kirsch, {Kathryn L.} and Thole, {Karen A.}",
year = "2018",
month = "1",
day = "1",
doi = "10.1115/GT2018-75429",
language = "English (US)",
isbn = "9780791851098",
series = "Proceedings of the ASME Turbo Expo",
publisher = "American Society of Mechanical Engineers (ASME)",
booktitle = "Heat Transfer",

}

Kirsch, KL & Thole, KA 2018, Numerical optimization, characterization, and experimental investigation of additively manufactured communicating microchannels. in Heat Transfer. Proceedings of the ASME Turbo Expo, vol. 5B-2018, American Society of Mechanical Engineers (ASME), ASME Turbo Expo 2018: Turbomachinery Technical Conference and Exposition, GT 2018, Oslo, Norway, 6/11/18. https://doi.org/10.1115/GT2018-75429

Numerical optimization, characterization, and experimental investigation of additively manufactured communicating microchannels. / Kirsch, Kathryn L.; Thole, Karen A.

Heat Transfer. American Society of Mechanical Engineers (ASME), 2018. (Proceedings of the ASME Turbo Expo; Vol. 5B-2018).

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

TY - GEN

T1 - Numerical optimization, characterization, and experimental investigation of additively manufactured communicating microchannels

AU - Kirsch, Kathryn L.

AU - Thole, Karen A.

PY - 2018/1/1

Y1 - 2018/1/1

N2 - The degree of complexity in internal cooling designs is tied to the capabilities of the manufacturing process. Additive manufacturing grants designers increased freedom while offering adequate reproducibility of micro-sized, unconventional features that can be used to cool the skin of gas turbine components. One such desirable feature can be sourced from nature; a common characteristic of natural transport systems is a network of communicating channels. In an effort to create an engineered design that utilizes the benefits of those natural systems, the current study presents wavy microchannels that were connected using branches. Two different wavelength baseline configurations were designed, then each were numerically optimized using a commercial adjointbased method. Three objective functions were posed to (1) minimize pressure loss, (2) maximize heat transfer, and (3) maximize the ratio of heat transfer to pressure loss. All baseline and optimized microchannels were manufactured using Laser Powder Bed Fusion for experimental investigation; pressure loss and heat transfer data were collected over a range of Reynolds numbers. The additive manufacturing process reproduced the desired optimized geometries faithfully. Surface roughness, however, strongly influenced the experimental results; successful replication of the intended flow and heat transfer performance was tied to the optimized design intent. Even still, certain test coupons yielded performances that correlated well with the simulation results.

AB - The degree of complexity in internal cooling designs is tied to the capabilities of the manufacturing process. Additive manufacturing grants designers increased freedom while offering adequate reproducibility of micro-sized, unconventional features that can be used to cool the skin of gas turbine components. One such desirable feature can be sourced from nature; a common characteristic of natural transport systems is a network of communicating channels. In an effort to create an engineered design that utilizes the benefits of those natural systems, the current study presents wavy microchannels that were connected using branches. Two different wavelength baseline configurations were designed, then each were numerically optimized using a commercial adjointbased method. Three objective functions were posed to (1) minimize pressure loss, (2) maximize heat transfer, and (3) maximize the ratio of heat transfer to pressure loss. All baseline and optimized microchannels were manufactured using Laser Powder Bed Fusion for experimental investigation; pressure loss and heat transfer data were collected over a range of Reynolds numbers. The additive manufacturing process reproduced the desired optimized geometries faithfully. Surface roughness, however, strongly influenced the experimental results; successful replication of the intended flow and heat transfer performance was tied to the optimized design intent. Even still, certain test coupons yielded performances that correlated well with the simulation results.

UR - http://www.scopus.com/inward/record.url?scp=85054060321&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=85054060321&partnerID=8YFLogxK

U2 - 10.1115/GT2018-75429

DO - 10.1115/GT2018-75429

M3 - Conference contribution

AN - SCOPUS:85054060321

SN - 9780791851098

T3 - Proceedings of the ASME Turbo Expo

BT - Heat Transfer

PB - American Society of Mechanical Engineers (ASME)

ER -

Kirsch KL, Thole KA. Numerical optimization, characterization, and experimental investigation of additively manufactured communicating microchannels. In Heat Transfer. American Society of Mechanical Engineers (ASME). 2018. (Proceedings of the ASME Turbo Expo). https://doi.org/10.1115/GT2018-75429