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AMANECO

AMANECO: ASSESSMENT OF ADDITIVE MANUFACTURING LIMITS FOR ECO-DESIGN OPTIMIZATION IN HEAT EXCHANGERS 

-Project start date: October 1st 2019
-Duration: 36 months (2019-2022)
-Total cost1.501.232,50 €

The project:

Selective Laser Melting (SLM) is key for improved design and production process of aviation parts. Applied to heat exchangers (HX), it could dramatically improve global eco‐efficiency through access to radically Additive manufacturing (AM) and in particular Selective Laser Melting (SLM) is a key technology for improved design and production process of aviation parts. Applied to heat exchangers (HX), it could dramatically improve global eco‐efficiency through access to radically new designs and open new horizons in terms of shape, weight, efficiency. Nevertheless, a lot remains to be done in order to perfectly master all the design and manufacturing process, as heat exchangers are complex and critical parts. Key questions to be solved are capability of AM to manufacture thin walls, small holes/gaps, low overhang angle, thin AM layers, resulting surface roughness, and resulting mechanical strength.

The main objective of the AManECO is to enhance knowledge of metal AM and, in particular, the capability of SLM process to manufacture thin layers and wall thickness with adequate surface finish. More specifically, to investigate aerothermal and mechanical performance of thin walls, to predict them in the design of AM-HX and consequently, be able to optimize the HX´s design process in an Eco-friendly way after knowing the limits of the metal AM technology.

The achievement of the technical objectives of AManECO will enable:

- To increase efficiency of Heat Exchangers up to 10%.
- To reduce the overall cost of the manufacturing of heat exchangers by 30%.
- To reduce material waste and scraps by 15 % per component.
- To reduce time-to market from several months to one month.

The achievement of these objectives will be supported by the multidisciplinary AManECO consortium, formed by experts in design and AM of heat exchangers (LORTEK and FTI), samples characterization (CIDETEC, MU-ENG), numerical simulation (EPSILON and TUHH), and life cycle assessment and eco-design (CTME).

Partnership:

- Coordination: Lortek S. Coop.
- Topic Management: Safran
- Partners:
   - LORTEK S COOP
   - TECHNISCHE UNIVERSITAT HAMBURG
   - FIT Production GmbH
   - EPSILON INGENIERIE
   - FUNDACION CENTRO TECNOLOGICO DE MIRANDA DE EBRO
   - FUNDACION CIDETEC
   - MONDRAGON GOI ESKOLA POLITEKNIKOA JOSE MARIA ARIZMENDIARRIETA S COOP

Our role:

The main role of CIDETEC within AMANECO project is the development and implementation of a chemical post-processing method for surface improvement in HXs components composed of thin and curved wall fins (in AlSi7Mg0.6 and INCO718) coupons additively manufactured. CIDETEC is also involved in the evaluation of surface properties and porosity characterization.

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