A Compact Low-loss Additive-manufactured Redirecting Heat Exchanger (CLARE): The evolution of aerodynamic efficiency

• Evoluted heat exchanger shows increased highspeed performance under oblique inflow • Staggering and contouring the leading edge have similar benefits • Homogenizing the inflow and reducing the leading edge separation is essential This paper presents the evolution of a matrix starting from a straight inlet-duct and targeting a staggered configuration with adapted edges and oblique inflow in three steps. Major loss mechanisms of each step are quantified using a comprehensive 3D CFD model. By the end, the heat exchanger enables an inlet velocity being 2.7 higher while increasing the pressure loss coefficient in the range between 5.3 % and 12.2 % in comparison to the same matrix under straight inflow. Further optimization potential is identified by reducing the leading edge flow separation and homogenizing the inflow into the matrix.