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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - TiltHex (Tilt Rotor Heat Exchanger)

Teaser

Summary

Heat exchangers are an essential part of aerospace engine and environmental control systems and impact upon engine efficiency and weight. The objective of this project is to realise innovations within the design and manufacture of aerospace heat exchangers by utilsiing advanced manufacturing techniques such as additive manufacturing and high speed machining. This includes innovations within the design, development, manufacture and test of an innovative Air Cooled Oil Cooler (ACOC) for Leonardo Helicopters civil tiltrotor transmission drive.

Improvements over conventional solutions will be made an based upon Marston Aerospace\'s recent development work in heat exchangers. The key objective is to produce a high efficiency, compact design that reduces the weight of the ACOC. By utilising advanced manufacturing techniques and eliminated welding from the manufacturing process the project also aims to increase the reliability and safety of future heat exchangers.

Work performed

The first period of the project was focused on assessing various heat transfer surfaces that could now be manufactured as a result of utilising alternative manufacturing techniques such as additive manufacturing. The goal of this activity was to identify innovative pin and fin geometries that would enable future heat exchangers to achieve the same heat rejection with lower weight and smaller overall dimensions.

The activity started with researching potential pin geometries. Different geometries were then analysed using Computational Fluid Dynamics (CFD) in order to rank and down-select the optimum geometries for the application.

Final results

By utilising the freedom of additive manufacturing, innovative pin geometries that outperform conventional geometries were identified during the first period. The next stage of the project will be to validate the analytical predictions by manufacturing and testing prototypes and confirming the suitability of the new geometries for the selected application.

If the testing of the prototypes proves successful, HS Marston are on the path to developing smaller, lighter heat exchangers that provide more flexibility for system integration!