Descripción del proyecto
Racionalizar la tecnología de sinterización selectiva por láser para intercambiadores de calor
Los fabricantes de motores de aviación han adoptado la fabricación aditiva para aprovechar las ventajas que ofrece esta tecnología para producir componentes complejos y de bajo volumen. La nueva libertad de diseño que ofrece la sinterización selectiva por láser (SLM) permite fabricar piezas de aeronaves complejas y ligeras con una mayor eficiencia y durabilidad. El proyecto AManECO, financiado con fondos europeos, se puso en marcha para abordar ciertos obstáculos relacionados con el uso de la SLM para fabricar intercambiadores de calor. El proyecto trabajará a fin de mejorar la capacidad de la SLM para fabricar capas de revestimiento finas, prestando especial atención a su rendimiento aerodinámico y mecánico. En conjunto, los resultados del proyecto ayudarán a aumentar la eficiencia de los intercambiadores de calor en un 10 %, a reducir los costes de fabricación en un 30 % y a reducir los residuos de material en un 15 %.
Objetivo
Selective Laser Melting (SLM) is key for improved design and production process of aviation parts. Applied to heat exchangers (HX), it could dramatically improve global eco‐efficiency through access to radically new designs and open horizons in terms of shape, weight, efficiency. Nevertheless, some questions need to be solved regarding capability of Additive Manufacturing (AM) to manufacture thin walls, small holes/gaps, low overhang angle, resulting surface roughness and mechanical strength.
AManECO aims to enhance knowledge of metal AM and, specifically, the capability of SLM process to manufacture thin layers and wall thickness with adequate surface finish using AlSi7Mg0.6 and INCO 718 materials. In particular, to investigate aerothermal and mechanical performance of thin walls, to predict them in the design of AM-HX and consequently, be able to optimize the HX´s design process in an Eco-friendly way after knowing the limits of the metal AM technology.
For this purpose, testing samples will be designed and manufactured to characterize in terms of surface properties, pressure resistance and gas tightness evaluation, equivalent stiffness and aerothermal properties. Besides, numerical studies based on FEM and CFD simulations will be done. Then, a representative design of HX based on the initial SOA of AM limitations will be optimized with the gained knowledge. These designs, before and after optimization, will be processed and characterized. Then, a Life Cycle Inventory (LCI) database will be created to evaluate the ECO potential of the innovative HX.
AManECO will enable to:
- Increase efficiency of HX up to 10%.
- Reduce the overall of HX manufacturing costs by 30%.
- Reduce material waste and scraps by 15 % per component.
- Reduce time-to market up to 1 month.
A multidisciplinary consortium, with experts in HX design and AM (TUHH, LORTEK, FIT), samples characterization (CIDETEC, MU-ENG), numerical simulation (EPSILON, TUHH), and life cycle assessment and eco-design (CTME), has been defined.
Ámbito científico
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Régimen de financiación
RIA - Research and Innovation actionCoordinador
20240 Ordizia
España