Mechanical Engineering Commons^™

Generative Designs Of Lightweight Air-Cooled Heat Exchangers, Connor Miller

Mechanical Engineering Undergraduate Honors Theses

The development of high-performance air-cooled heat exchangers is required to permit the rapid growth of vehicle and aircraft electrification. In electric vehicles and airliners, the motors and power electronics are integrated into a compact space, leading to unprecedently high power density. To achieve higher overall thermal efficiency, the heat exchangers must be extremely light while maintaining their heat transfer performance and mechanical robustness. Recently advances in 3D metal printing, e.g., direct metal laser sintering, and selective laser melting, have enabled the manufacturing of high-performance robust heat exchangers by eliminating thermal boundary resistance and ensuring a uniform thermal expansion coefficient. Nonetheless, …