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New Additive manufacTuring Heat ExchaNger for Aeronautic

Periodic Reporting for period 2 - NATHENA (New Additive manufacTuring Heat ExchaNger for Aeronautic)

Reporting period: 2019-09-01 to 2021-02-28

The aim of "New AddiTive manufacturing Heat ExchaNger for Aeronautic" project is to develop a complex compact air-air heat exchange design by additive manufacturing. The new exchanger will provide an efficient thermal management system dedicated to hybrid propulsion system.
Usually, a poor design of the distributor may cause a loss of efficiency of the heat exchanger. The use of "additive layer manufacturing" step allow to improve design of the whole heat exchanger unit design and therefore the performance and the robustness/compactness the thermal system.

Accordingly, the research activities of the NATHENA project focus on the following four main objectives :
1. Adaptability and modularity of the internal structure and global modelling of the Compact Heat exchanger: this approach will allow to propose a modular heat exchanger and to adapt any kind of local structure to any global sizing with the best thermo-hydraulic performances and with a minimized mass.
2. Reconstruction of a CAD (Computer Aided Design) model with a Representative Model obtained from the simulation to harmonized methodologies will then make it possible to generate the complex structure of the heat exchanger.
3. Additive manufacture of innovative heat exchanger allowing mass reduction and/or performance improvement.
4. Aerothermal diagnostic of compact heat exchanger evolutionary structures: to conduct detailed experimental determination of the aerothermal performance of new concept of
compact heat exchanger.

The outcome for this new complex and compact heat exchanger will lead to a lighter and more performant heat exchanger. These two features will directly lead to a reduction of fuel consumption. In addition, the development of new generation of heat exchangers manufactured in 3D printing will participate to the ecological transition with a less consummation of raw materials and a strong limitation waste.
The WP1 concerns financial, risk and project management activities.
The rigorous management of the project allows and will allow to reach the technical impacts that we have targeted.

During the reporting Period, the WP2 has been finished. We have established the state of art about the heat exchangers, dealing with design, simulation, optimization, manufacturing and tests. A state of the art of patents has been performed also.

The WP3 concerns the improvement of selected structures in accordance with defined parameters. The different thermal and mechanical simulations led on the structures allowed the consortium to approach the final heat exchanger internal structure pattern.

The WP4 concerns the tests of single elementary channels of the simplify heat exchanger made at this step of NATHENA project. Dedicated test facilities by means of advanced measurement techniques have been developed for NATHENA project.

The WP7 deals with Innovation management. We have submitted to the EC, a Data Management Plan & the Plan for Exploitation and Dissemination of results. Also, an article has been dedicated to NATHENA on every partner website and a first newsletter has been communicated on different media (partners website, linkedin ...).
About the compact heat exchanger, the ambition of NATHENA Project is to push over limitations of current global compact heat exchanger design by using additive manufacturing, new methodologies of simulations and design, to optimize a new compact heat exchanger.
We aim to reach the following theoretical target :
Delta temperature: 200°C to 400°C
Flow: 0.01kg/s to 2kg/s
Power: 0.5 to 500kW
Reynolds number: 400 to 10000
Pressure drop: 100mBar max
Size: up to 500x300x300mm
The values achieved during the tests will depend on the capacities of the test facilities.

Today, at the first reporting period, results from NATHENA deliver outstanding benefits.
For example, the test facilities developed will be able to be to open new perspectives to European industrials and academic institutions in order to transpose the developments to other infrastructure, testing capabilities and funding.
Likewise, the expertise gained for the instrumentation of elements made by additive manufacturing will be able to be reused in any new research involving additive manufacturing pieces.
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