The development of aerospace heat exchanger technology stagnated for many years as designers and manufacturers were limited by the constraints of conventional manufacturing processes. However, the evolution of new processes such as high-speed machining and additive manufacturing are removing constraints imposed by conventional manufacturing processes and are enabling the design and manufacture of innovative heat exchangers. By utilising advanced manufacturing techniques such as high speed machining and additive manufacturing, aerospace heat exchangers can become smaller, lighter, and more efficient.
As technology has developed and the limitations of conventional manufacturing process are removed, the demand on aerospace thermal management products has increased rapidly. Thermal dissipation requirements have increased and space availability has decreased. Moreover, environmentally aware consumers and growing legislation are forcing aircraft manufacturers to develop quieter and more fuel efficient aircraft. These demands are driving products such as heat exchangers to become lighter, smaller, more efficient and easier to integrate within other systems of the aircraft. By increasing the efficiency of heat exchangers, aero-engine fuel efficiency will be improved which subsequently reduce the carbon footprint to benefit our society and help address environmental challenges today's generation face.
HS Marston Aerospace, a Collins Aerospace organisation, is one of the world’s leading suppliers in heat transfer and fluid management products for the military and commercial aerospace markets and electronics industries. The organisation boasts an impressive 275 year history and has provided aerospace products for over 100 years. Under the framework of the H2020 programme, HS Marston Aerospace set out to develop an innovative Air Cooled Oil Cooler heat exchanger for Safran Helicopter Engine’s TurboProp demonstrator. The objective was to deliver an innovative heat exchanger that utilised the freedom offered by advanced manufacturing techniques in order to help reduce overall system weight, reduce fuel consumption, and improve reliability and safety. Additionally, the project will aim to reduce waste material through the manufacturing process, decrease the development time of future products, and sustain engineering jobs within the European Economic Area.
