Lightweight structure of a phase-change thermal controller based on lattice cells manufactured by SLM
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摘要
Thermal controllers equipped with phase-change materials are widely used for maintaining the moderate temperatures of various electric devices used in spacecraft. Yet, the structures of amounts of thermal controllers add up to such a large value that restricts the employment of scientific devices due to the limit of rocket capacity. A lightweight structure of phase-change thermal controllers has been one of the main focuses of spacecraft design engineering. In this work, we design a lightweight phase-change thermal controller structure based on lattice cells. The structure is manufactured entirely with AlSi10 Mg by direct metal laser melting. The dimensions of the structure are 230 mm × 170 mm × 15 mm, and the mass is 190 g, which is 60% lighter than most traditional structures(500–600 g) with the same dimensions. The 3 D-printed structure can reduce the risk of leakage at soldering manufacture by a welding process. Whether the strength of the designed structure is sufficient is determined through mechanical analysis and experiments. Thermal test results show that the thermal capacity of the lattice-based thermal controller is increased by50% compared to that of traditional controllers with the same volume.
Thermal controllers equipped with phase-change materials are widely used for maintaining the moderate temperatures of various electric devices used in spacecraft. Yet, the structures of amounts of thermal controllers add up to such a large value that restricts the employment of scientific devices due to the limit of rocket capacity. A lightweight structure of phase-change thermal controllers has been one of the main focuses of spacecraft design engineering. In this work, we design a lightweight phase-change thermal controller structure based on lattice cells. The structure is manufactured entirely with AlSi10 Mg by direct metal laser melting. The dimensions of the structure are 230 mm × 170 mm × 15 mm, and the mass is 190 g, which is 60% lighter than most traditional structures(500–600 g) with the same dimensions. The 3 D-printed structure can reduce the risk of leakage at soldering manufacture by a welding process. Whether the strength of the designed structure is sufficient is determined through mechanical analysis and experiments. Thermal test results show that the thermal capacity of the lattice-based thermal controller is increased by50% compared to that of traditional controllers with the same volume.
Thermal controllers equipped with phase-change materials are widely used for maintaining the moderate temperatures of various electric devices used in spacecraft. Yet, the structures of amounts of thermal controllers add up to such a large value that restricts the employment of scientific devices due to the limit of rocket capacity. A lightweight structure of phase-change thermal controllers has been one of the main focuses of spacecraft design engineering. In this work, we design a lightweight phase-change thermal controller structure based on lattice cells. The structure is manufactured entirely with AlSi10 Mg by direct metal laser melting. The dimensions of the structure are 230 mm × 170 mm × 15 mm, and the mass is 190 g, which is 60% lighter than most traditional structures(500–600 g) with the same dimensions. The 3 D-printed structure can reduce the risk of leakage at soldering manufacture by a welding process. Whether the strength of the designed structure is sufficient is determined through mechanical analysis and experiments. Thermal test results show that the thermal capacity of the lattice-based thermal controller is increased by50% compared to that of traditional controllers with the same volume.
引文
1.Schelden BG,Golden JO.Development of a phase change thermal control device.J Spacecraft Rockets 1973;10(2):99-100.
2.Peterson GP,Ortega A.Thermal control of electronic equipment and devices.Adv Heat Transf 1990;20:181-314.
3.Kandasamy R,Wang XQ,Mujumdar AS.Application of phase change materials in thermal management of electronics.Appl Therm Eng 2007;27:2822-32.
4.Ling Z,Zhang Z,Shi G,et al.Review on thermal management systems using phase change materials for electronic components,Li-ion batteries and photovoltaic modules.Renew Sustain Energy Rev 2014;31:427-38.
5.Darkwa J,Su O,Zhou T.Evaluation of thermal energy dynamics in a compacted high-conductivity phase-change material.J Thermophys Heat Tr 2015;29(2):1-6.
6.Pal D,Joshi YK.Thermal Management of an avionics module using solid-liquid phase-change materials.J Thermophys Heat Tr1998;12(2):256-62.
7.Nofal M,Pan Y,Al-Hallaj S.Selective laser sintering of phase change materials for thermal energy storage applications.Proc Manuf 2017;10:851-65.
8.Tang M,Pistorius PC.Anisotropic mechanical behavior of AlSi10Mg parts produced by selective laser melting.JOM:JMinerals,Met Mater Soc 2017;69(3):1-7.
9.Tsopanos S,Mines RAW,McKown S,et al.The influence of processing parameters on the mechanical properties of selectively laser melted stainless steel microlattice structures.J Manuf Sci Eng2010;132(4):1-12.
10.Gibson I,Rosen DW,Stucker B.Additive manufacturing technologies:rapid prototyping to direct digital manufacturing.New York:Springer;2009.
11.Yan C,Hao L,Hussein A,Young P,Huang J.Microstructure and mechanical properties of aluminium alloy cellular lattice structures manufactured by direct metal laser sintering.Mater Sci Eng A2015;628:238-46.
12.Kim T,Zhao CY,Lu TJ,Hodson HP.Convective heat dissipation with lattice-frame materials.Mech Mater 2004;36(8):767-80.
13.Karen NS,Justin AW,Vellaisamy K,Suresh VG.Design of multifunctional lattice-frame materials for compact heat exchangers.Int J Heat Mass Tran 2017;115(Part A):619-29.
14.Lu TJ,Valdevit L,Evans AG.Active cooling by metallic sandwich structures with periodic cores.Prog Mater Sci 2005;50(7):789-815.
15.Kim T,Hodson HP,Lu TJ.Fluid-flow and endwall heat-transfer characteristics of an ultralight lattice-frame material.Int J Heat Mass Tran 2004;47(6-7):1129-40.
16.Deshpande VS,Ashby MF,Fleck NA.Foam topology bending versus stretching dominated architectures.Acta Mater2001;49:1135-40.
17.Louvis E,Fox P,Sutcliffe CJ.Selective laser melting of aluminium components.J Mater Process Tech 2011;211(2):275-84.
18.Zheng LJ,Liu YY,Sun SB,Zhang H.Selective laser melting of Al-8.5Fe-1.3V-1.7Si alloy:investigation on the resultant microstructure and hardness.Chin J Aeronaut 2015;28(2):564-9.
19.Gu DD,Meiners W,Wissenbach K,Poprawe R.Laser additive manufacturing of metallic components:materials,processes and mechanisms.Int Mater Rev 2012;57(3):133-64.
20.Fan FL,Fang DN,Jing FN.Yield surfaces and micro-failure mechanism of block lattice truss materials.Mater Des 2008;29(10):2038-42.
21.Sing SL,Yeong WY,Wiria FE,Tay BY.Characterization of titanium lattice structures fabricated by selective laser melting using an adapted compressive test method.Exp Mech 2016;56(5):735-48.
2.Peterson GP,Ortega A.Thermal control of electronic equipment and devices.Adv Heat Transf 1990;20:181-314.
3.Kandasamy R,Wang XQ,Mujumdar AS.Application of phase change materials in thermal management of electronics.Appl Therm Eng 2007;27:2822-32.
4.Ling Z,Zhang Z,Shi G,et al.Review on thermal management systems using phase change materials for electronic components,Li-ion batteries and photovoltaic modules.Renew Sustain Energy Rev 2014;31:427-38.
5.Darkwa J,Su O,Zhou T.Evaluation of thermal energy dynamics in a compacted high-conductivity phase-change material.J Thermophys Heat Tr 2015;29(2):1-6.
6.Pal D,Joshi YK.Thermal Management of an avionics module using solid-liquid phase-change materials.J Thermophys Heat Tr1998;12(2):256-62.
7.Nofal M,Pan Y,Al-Hallaj S.Selective laser sintering of phase change materials for thermal energy storage applications.Proc Manuf 2017;10:851-65.
8.Tang M,Pistorius PC.Anisotropic mechanical behavior of AlSi10Mg parts produced by selective laser melting.JOM:JMinerals,Met Mater Soc 2017;69(3):1-7.
9.Tsopanos S,Mines RAW,McKown S,et al.The influence of processing parameters on the mechanical properties of selectively laser melted stainless steel microlattice structures.J Manuf Sci Eng2010;132(4):1-12.
10.Gibson I,Rosen DW,Stucker B.Additive manufacturing technologies:rapid prototyping to direct digital manufacturing.New York:Springer;2009.
11.Yan C,Hao L,Hussein A,Young P,Huang J.Microstructure and mechanical properties of aluminium alloy cellular lattice structures manufactured by direct metal laser sintering.Mater Sci Eng A2015;628:238-46.
12.Kim T,Zhao CY,Lu TJ,Hodson HP.Convective heat dissipation with lattice-frame materials.Mech Mater 2004;36(8):767-80.
13.Karen NS,Justin AW,Vellaisamy K,Suresh VG.Design of multifunctional lattice-frame materials for compact heat exchangers.Int J Heat Mass Tran 2017;115(Part A):619-29.
14.Lu TJ,Valdevit L,Evans AG.Active cooling by metallic sandwich structures with periodic cores.Prog Mater Sci 2005;50(7):789-815.
15.Kim T,Hodson HP,Lu TJ.Fluid-flow and endwall heat-transfer characteristics of an ultralight lattice-frame material.Int J Heat Mass Tran 2004;47(6-7):1129-40.
16.Deshpande VS,Ashby MF,Fleck NA.Foam topology bending versus stretching dominated architectures.Acta Mater2001;49:1135-40.
17.Louvis E,Fox P,Sutcliffe CJ.Selective laser melting of aluminium components.J Mater Process Tech 2011;211(2):275-84.
18.Zheng LJ,Liu YY,Sun SB,Zhang H.Selective laser melting of Al-8.5Fe-1.3V-1.7Si alloy:investigation on the resultant microstructure and hardness.Chin J Aeronaut 2015;28(2):564-9.
19.Gu DD,Meiners W,Wissenbach K,Poprawe R.Laser additive manufacturing of metallic components:materials,processes and mechanisms.Int Mater Rev 2012;57(3):133-64.
20.Fan FL,Fang DN,Jing FN.Yield surfaces and micro-failure mechanism of block lattice truss materials.Mater Des 2008;29(10):2038-42.
21.Sing SL,Yeong WY,Wiria FE,Tay BY.Characterization of titanium lattice structures fabricated by selective laser melting using an adapted compressive test method.Exp Mech 2016;56(5):735-48.