Ultra-Compact Heat Exchanger
PSI ultra-compact heat exchanger for any application.
PSI’s additively manufactured heat exchanger can adapt to the performance and geometry needs of any application.
Capability Description: Current aircraft thermal management systems are unable to meet the increasing heat rejection requirements of newer, energy dense technologies. Existing heat exchangers are also bulky and their rectangular shape is not adaptable to the unique volume spaces that are available on space-constrained aircraft. PSI’s Ultra-Compact Heat Exchanger (UCHX) employs an adaptive design that can be readily tailored to fit into existing volumes while also conforming to maximize performance for the given thermofluidic conditions. PSI has also developed the thin-wall printing capabilities needed to additively manufacture our heat exchanger geometry in a number of different materials, such as aluminum and nickel alloys, using our SLM125 metal printer.
Key Features: PSI’s UCHX makes use of several critical technologies to bring weight-saving and heat transfer performance benefits to any application:
- PSI has developed a conformal AM heat exchanger that can be readily adapted to fit into existing volume on aircraft or pods that is currently wasted
- Prior work has already demonstrated impermeable AM heat exchangers with wall thickness down to 254 μm to maximize heat transfer to weight ratio
- Demonstrated 6.6 kW/kg of heat transfer at 81% effectiveness for liquid-gas application
Benefits: PSI’s UCHX technology directly addresses the defense-related mission need for high-performance airborne heat exchangers. As thermal loads increase across all aircraft due to greater power, electrification, and inclusion of directed energy weapons, a greater density of heat rejection is required. Compact, lightweight heat exchangers, such as PSI’s UCHX, will allow for this increased heat rejection and enable the deployment of other advanced technologies. Furthermore, the UCHX has the potential to improve the efficiency of thermally dependent devices such as direct energy weapons and maintain safe operating temperatures for high power electronics and similar equipment.