Design and Implementation of a Tube Heat Exchanger for Turbojet Engines to Improve Operational Efficiency

Heat exchangers are widely used across various industries to transfer heat between two fluids: liquid or gas without direct contact. In turbojet engines operating at high temperatures, heat exchangers are essential for cooling lubricants, improving engine efficiency, and minimizing lubricant degradation. Shell‐and‐tube heat exchangers are preferred in aircraft engines for their compact size and high thermal efficiency. The development of such heat exchangers involves several steps, including selecting the appropriate number of tubes, calculating the cooling rate, and conducting reliability tests before and after fabrication. After reviewing multiple manufacturing parameters and evaluating the suitability for the target aircraft engine, we established a comprehensive three‐step fabrication process. First, numerical calculations were carried out to estimate the required number of tubes and shells. Next, computational fluid dynamics (CFD) analysis using ANSYS Fluent was conducted to validate the numerical results and perform parametric studies. Finally, a new heat exchanger design was fabricated and tested to evaluate its efficiency under real‐world operating conditions.