Objective

Selective Laser Melting (SLM) is key for improved design and production processes 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 and efficiency. Nevertheless, some problems need to be solved regarding capability of Additive Manufacturing (AM) to manufacture thin walls, small holes/gaps, low overhang angles, resulting surface roughness and mechanical strength. AManECO aims to enhance knowledge of metal AM and, specifically, the capability of the SLM process to manufacture thin layers and wall thicknesses 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-HXs 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 be then characterized 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 produced and characterized. Then, a Life Cycle Inventory (LCI) database will be created to evaluate the ECO potential of the innovative HX.

Website: https://amaneco.eu

Duration: 01.10.2019 - 30.09.2022

Staff member in charge: Tim Röver

Funding programme: JTI-CS2-2018-CfP09-ENG-01-42 - Additive manufacturing boundary limits assessment for Eco Design process optimization

Project management agency: CleanSky 2

Project partners:

• Safran (Topic Manager)
• Lortek S. Coop.
• FIT Production GmbH
• Epsilon Ingenierie 
• Fundación Centro Tecnológico de Miranda de Ebro 
• Fundación Cidetec 
• Mondragon Goi Eskola Politeknikoa Jose Maria Arizmendiarrieta S. Coop.

This project has received funding from the Clean Sky 2 Joint Undertaking (JU) under grant agreement No 864733. The JU receives support from the European Union’s Horizon 2020 research and innovation programme and the Clean Sky 2 JU members other than the Union.