The development of a high-performance Ni-superalloy additively manufactured heat pipe

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The development of a high-performance Ni-superalloy additively manufactured heat pipe

Sheng Li , Khamis Essa , James Carr , States Chiwanga , Andrew Norton , Moataz M. Attallah

Advances in Manufacturing ›› 2022, Vol. 10 ›› Issue (4) : 610 -624.

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Advances in Manufacturing ›› 2022, Vol. 10 ›› Issue (4) : 610 -624. DOI: 10.1007/s40436-022-00407-z

Article

The development of a high-performance Ni-superalloy additively manufactured heat pipe

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¹ School of Electromechanical Engineering, Guangdong University of Technology, 510006, Guangzhou, People’s Republic of China

² School of Engineering, University of Birmingham, Edgbaston, B15 2TT, Birmingham, UK

³ Henry Moseley X-ray Imaging Facility, Henry Royce Institute for Advanced Materials, Department of Materials, University of Manchester, M13 9PL, Manchester, UK

⁴ European Thermodynamics Ltd, 8 Priory Business Park, Wistow Road, Kibworth, LE8 0RX, Leicestershire, UK

⁵ Rolls-Royce plc, P.O. Box 31, DE24 8BJ, Derby, UK

⁶ School of Metallurgy and Materials, University of Birmingham, Edgbaston, B15 2TT, Birmingham, UK

^f m.m.attallah@bham.ac.uk

Sheng Li received Ph.D. degree in Materials Science from University of Birmingham, UK, in 2017. He is currently working as a research fellow in the School of Metallurgy and Materials, University of Birmingham. He is the author of 24 research publications. His research interests include additive manufacturing of metal and ceramic, processing and microstructure of shape memory alloys, Ni superalloys, Ti alloys, Al alloys and metal matrix composite. He has worked on the projects supported by leading companies across the world including Rolls-Royce, Airbus, Honda, BAE Systems, MBDA Missiles, MicroTurbo, Ford, and European Space Agency.

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Khamis Essa is Reader in Advanced Manufacturing and Process Modelling at the School of Engineering, the University of Birmingham and the Director of the Advanced Manufacturing Group. His research is focused on advanced manufacturing technologies for instance Metal and ceramic 3D printing, Hot Isostatic Pressing and Incremental Sheet Forming. He has been developing novel manufacturing routes and applications for aerospace, defence, automotive and biomedical industries. The scientific emphasis of his research is on material and process interaction. He has been leading a number of research projects funded by EU, UK research councils and industry. His research has been supporting major companies across the world including Rolls-Royce, BAE Systems, MBDA Missiles, MicroTurbo, Ford, European Space Agency and Caterpillar. Dr Essa has over 80 journal and conference publications in addition to two patents and one book. He is guest editor for the micromechanics journal and is setting on the editorial board of three other international journals.

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James Carr received his MPhys degree in 2008 and Ph.D. degree in Materials Science in 2014 from the University of Manchester. James Carr is an Applications Specialist for MicroCT at Blue Scientific. He acquired his first degree in Physics at the University of Manchester in 2008 and then a PhD in Materials Science in 2015. He has spent his research career specializing in 3D imaging and image processing at the Henry Moseley X-ray Imaging Facility and Diamond Light Source.

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States Chiwanga received his BSc degree in Aeronautical Engineering from University of Salford, UK and his MSc degree in Fluid Mechanics from Washington State University, USA. States has worked in senior positions for well-known multinational engineering companies including Schlumberger, Solectron and PDD Group before starting Cambridge Engineering Analysis and Design Ltd. (CEAD) in 2007. He is now the director/CFD &Thermofluids Consultant in CEAD.

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Andrew Norton received his MSci in Natural Sciences (Materials Science) from University of Cambridge and DPhil (Ph.D.) degree in Materials from University of Oxford, UK in 2013. He is now work as technologist and managing the projects gear-funded through Aerospace Technology Institute &InnovateUK, involving collaborations with a number of Rolls-Royce University Technology Centres and Small/Medium-Sized Enterprises, and utilise a global Research & Development supply chain network. Including the development of novel systems to perform inspection and repair inside aeroengines, emerging technologies (typically Technology Readiness Level 6 and below), supporting the movement of on-wing inspection and repair technologies into production through a wide ranging supply chain network.

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Moataz M. Attallah holds a chair in advanced materials processing at the School of Metallurgy and Materials University of Birmingham. His research focuses on developing a metallurgical understanding of the material-process interaction in additive manufacturing of metallic materials focusing on the process impact on the microstructure and structural integrity development. His research is conducted through research partnerships with various companies in the aerospace, defence, medical, space, and nuclear energy sectors. He co-authored over 170 journal and conference papers, 3 book chapters, and is a co-inventor on 8 patent applications.

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Abstract

Additively manufacturing (AM) has been used to manufacture fine structures with structured/engineered porosity in heat management devices. In this study, laser powder bed fusion (LPBF) was used to manufacture a high-performance Ni-superalloy heat pipe, through tailoring LPBF process parameters to fabricate thin wall and micro-channel. By using novel laser scanning strategies, wick structure heat pipes with maximised surface-area-to-volume ratio, fine features size around 100 µm, and controlled porosity were successfully fabricated. Microscopy and X-ray microtomography (micro-CT) were used to investigate the 3D structure of the void space within the pipe. Wick test results showed that most of the heat pipes made by LPBF had better performance than the conventionally manufactured pipes. This study also investigated the influences of the process parameters on the porosity volume fraction and the feature size. The results showed that LPBF process could fabricate thin structure due to the change of melt pool contact angle. The relationship between process parameters and bead size reported in this study could help design and manufacture heat pipe with complex fine structure.

Keywords

Laser powder bed fusion (LPBF) / Heat pipe / Melt pool / Microtomography (micro-CT)

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Sheng Li, Khamis Essa, James Carr, States Chiwanga, Andrew Norton, Moataz M. Attallah. The development of a high-performance Ni-superalloy additively manufactured heat pipe. Advances in Manufacturing, 2022, 10(4): 610-624 DOI:10.1007/s40436-022-00407-z

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Funding

rolls-royce http://dx.doi.org/10.13039/501100000767(Advanced Repair Technologies (113015) programme)

engineering and physical sciences research council http://dx.doi.org/10.13039/501100000266(EP/F007906/1)

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