thermal management of fuel cell systems using metal ... · case studies of additive manufacturing...
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© HiETA Technologies Ltd 2018 - The information in this presentation contains confidential and/or privileged material. You are hereby notified that any disclosure, copying, distribution or use of the information contained herein or in any attachment is strictly prohibited.
Thermal management of fuel cell systems using metal additive manufacturing
13th March 2018
The 14th International Hydrogen and Fuel Cell Conference
NEC, Birmingham
Desi Bacheva
© HiETA Technologies Ltd 2016
Content
Introduction to HiETA
Technology introduction
Case studies of Additive Manufacturing Phase-change heat exchanger for PEM fuel cells
Conclusions
© HiETA Technologies Ltd 2016
HiETA Technologies
Specialists in thermal management and lightweighting solutions enabled by Additive Manufacturing (AM)
Established 6 years with approximately 40 staff
Running 9 Powder Bed AM Machines
Based in Bristol and Bath Science Park
© HiETA Technologies Ltd 2016
Myriad technologies
“joining of materials, usually by layers, to create products from 3D model data”
Our focus is metal powder-bed processes
Key inputs:Laser Power
Powder
Data
Argon flow
Many other considerations….
Metal Additive Manufacturing
© HiETA Technologies Ltd 2016© HiETA Technologies Ltd 2018 - The information in this presentation contains confidential and/or privileged material. You are hereby notified that any disclosure, copying, distribution or use of the information contained herein or in any attachment is strictly prohibited.
Rapid Product Development
Benefits of AM
Micro Gas Turbine Range Extender
Recuperator
Inverted Brayton cycle exhaust heat
recovery system
Lightweight/
Lightweight and cooled turbine
wheel for turbocharger
Thermal Efficiency/ Energy
Recovery
Customisation/High Value Low Volume Parts
Package Space Reductions
Heat exchanger formed around turbo machinery
for reduced package spacing
3 months from requirements to
demonstrator
2kW of energy recovery from exhaust
heat
Approx. 25% reduction in mass
40% reduction in product volume
© HiETA Technologies Ltd 2016
HiETA Products
COMPONENTS
Low temp heat
exchanger
High efficiency integrated micro
gas turbine
Inverted Brayton Cycle waste heat
recovery
Modular heat exchanger
High temp heat
exchanger
Turbo machinery
Fuel & combustion
Multi-functional & Lightweight
Design EngineeringServices
Additive ManufacturingServices
TestingServices
1D AnalysisCFD, FEA & Topology OptimisationConceptual & detailed design
Renishaw AM250 & Ren AM500M machinesAlSi10Mg, Ti6Al4VInc625, Inc718, CM247LC
Heat transfer surface characterisationLow temperature heat exchangersPhase change heat exchangersNDI/NDT services
Water cooled charge air coolers
Phase-change condensers
Annular recuperators
Cuboid recuperators
Solid turbine wheels
Cooled turbine wheels
Cooled compressors
Fuel cooling injectorsClassification Unclassified TECHNICAL
REPORT Export Rating UK
Doc No: 001678_1 Characterisation,of,Porous,Lattice,Structures,for,Combustor,Fuel,Injector,using,AM
Page: 12 Issue: 1
HiETA Technologies Ltd. This document and associated information is confidential and privileged material. You are hereby notified that any disclosure,
copying, distribution without explicit written permission from HiETA Technologies Ltd is strictly prohibited.
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Fig,5,shows,some,of,the,manufactured,Gyroid,lattice,samples.,,
,FigureD6,Flow,rate,vs.,pressure,gradient,,
,
Porous injectors & filters
Integrated combustors
Combined structural & cooling
Penetrating & double lap joining
Hybrid truss & mass customisation
SYSTEMS
© HiETA Technologies Ltd 2016
Additive Manufacturing Value Chain
Maximum performance
Least weight design
Minimum cost
Quality
© HiETA Technologies Ltd 2016© HiETA Technologies Ltd 2018 - The information in this presentation contains confidential and/or privileged material. You are hereby notified that any disclosure, copying, distribution or use of the information contained herein or in any attachment is strictly prohibited.
What is the cost?
© HiETA Technologies Ltd 2016
Conventional geometries
HiETA proprietary geometries, fabricated via additive manufacturing, have a “volume goodness factor” up to 5 x greater than conventional geometries, meaning HiETA heat exchangers can be up to 5 x smaller.
4L vs 15LCharge air cooler
8L vs 54L2kWe CHP
4L vs 51L30kW Range Extender
70kg vs 1.5T!400 kW CHP
Optimised HX Design
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Case Study
© HiETA Technologies Ltd 2016
Additive Manufacture for Automotive Fuel CellSystem (AMAFS)
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Introduction
Problem statement: Fuel Cell Electric Vehicles have a significant potential to reduce CO2 emissions in the future car fleet. In PEM fuel cell systems, the requisite heat exchanger and auxiliary elements represent a major element of the cost and performance as well as driving the output power density of the system.
Project Objective: To utilise metal additive manufacturing to progressively develop and demonstrate an innovative phase-change heat exchanger for an automotive Fuel Cell system.
© HiETA Technologies Ltd 2016
HX Design: Considerations
Inlet Duct
Pre-separation
Post-separation
Core
Outlet Duct
Material: Stainless steel 316L
Design driven by:
- Performance requirements: Thermal duty 34.5 KW
- Physical requirements: weight, volume, footprint
- Manufacturing requirements: Design for AM
- CAD file size and build file processing
© HiETA Technologies Ltd 2016
HX Design: Development Cycle
Test rig design, experimental evaluation
and validation of CFD model
1-D sizing and Concept Generation
Single tube isothermal CFD and shape
optimization for max heat transfer and min
pressure drop
Test blocks design and manufacture
© HiETA Technologies Ltd 2016
HX Design: Considerations
▪ Parametric model of creating original hot- and cold-fluid geometry to produce better quality surfaces that have more efficient packing.
▪ Reduced hot – to – cold separation
▪ Better nesting of hot and cold fluids resulting in increased compactness
▪ Cold-fluid bridging to reduce mass
▪ Multiple coolant headers to improve coolant distribution
Half HX core
© HiETA Technologies Ltd 2016
Summary
This project has been successful in demonstrating the potential of AM to significantlyimprove the output power density of automotive fuel cell systems. This is achievedthrough increased performance of its thermal management system, reducedpackaging and component intergration.
Benefits powder-bed metal AM can be realised if:
Choose the “right” part/system
Design team willing/empowered to innovate, specifically design for process and function
Ability to integrate can unlock many benefits – overcome short term cost challenges
Optimise both process and post-processing stages
Hardware is progressing and build times are reducing
Technology is no longer simply “Emerging”
High-value low-volume applications & full supply chain volume production is achievable
The key is maximising the value at a system level
© HiETA Technologies Ltd 2016
Thank you for your attention
Desi Bacheva
Customer Validation Lead
HiETA Technologies Ltd