Thermal Stress Analysis of Compact Heat Exchanger Produced by Additive Manufacturing

Abstract Compact heat exchangers are renowned for their high heat transfer rates and efficiency, achieved by incorporating mini and microchannels in their core design. However, operating under conditions of high-pressure fluctuations and significant temperature differences between hot and cold streams can potentially induce fatigue failure. To the best of our knowledge, this study represents the first investigation into the thermal stresses experienced by heat exchanger samples manufactured by selective laser melting (SLM) technology, focusing on circular channels. Experiments were conducted using hot water in the inner channel, while the remaining channels and the sample surface were subjected to natural convection in ambient air. Strain gauges, thermocouples, and resistance temperature detector (RTDs) were employed to measure strain and temperature variations over time. These data were utilized as inputs for a numerical model based on finite element method (FEM). The strain measurements were compared with those obtained from the numerical model, revealing an average difference of approximately 20%. Lastly, a thermal fatigue analysis based on the maximum equivalent stresses predicted by the numerical model is presented. The evaluation considered both S–N curves: outlined in the ASME standard and the one obtained with specimens produced through selective laser melting. In the case of circular channels manufactured through additive manufacturing evaluated in this work, thermal stresses alone are insufficient to cause component failure due to fatigue. However, significant pressure cycles superimposed on the model can reverse this situation, making the combined effect of thermal and mechanical stresses influential in determining the component's fatigue behavior.