INVESTIGATION OF THERMAL AND FLUID FLOW CHARACTERISTICS OF AM SURFACES WITH DIFFERENT BUILD ORIENTATIONS THROUGH CFD AND EXPERIMENTS

Additive manufacturing (AM), particularly laser powder bed fusion (LPBF), is of great interest to the aerospace community as it can be used to manufacture parts with complex internal and external geometries. This is in contrast to conventional manufacturing methods that limit the complexity of part designs. Of particular interest are the manufacture of parts with cooling channels consisting of complex surface topographies designed to improve thermal performance of the channels. While conventional machining can reduce the roughness of external surfaces, most surface treatment processes cannot be applied to internal channels, especially when the dimensions are a millimeter or submillimeter scale. Additive manufacturing offers an alternative that has the potential to overcome this limitation.
For a successful industrial adoption of AM for parts requiring complex cooling channels, an understanding of the relationship between the as-built surface finish and heat transfer is needed. In LPBF, there are numerous build parameters, such as part orientation during the build, that affect the final part surface topography and hence heat transfer. The classic literature on the impact of surface roughness on heat transfer (Moody's diagram) uses a simplified treatment of surface roughness, while powder bed fusion processes generate complex surfaces with strong anisotropic features, spatter, and surface and subsurface defects, all of which may affect heat transfer and fluid flow.
The primary focus of this work is to study the effects of AM roughness characteristics (build orientations, density of spatter deposits and their sizes, amplitudes/wavelengths, etc.) on heat transfer from the corresponding AM surfaces and pressure drop across cooling channels. Both numerical and experimental investigations are carried out for this purpose. Computational Fluid Dynamics (CFD) models for mini-channels using StarCCM+ (a commercial CFD code) were developed by acquiring the roughness data from real AM surfaces with various roughness parameters. To explore the correlation between sand-grain modeled roughness and AM surface roughness with 90° build orientation, CFD simulations for the entire system model (experimental setup) were employed. Further, CFD modeling of mini-channels with different wavy surfaces helped in determining the suitable dimensions for the mini-channel experimental set-up and the range of Reynolds numbers necessary for carrying out relevant experiments. Based on CFD findings, an exchangeable experimental setup was developed and on the basis of roughness characterizations, the AM parts with three critical orientations (0°, 45°, and 90°) were fabricated and then machined to the required shape and size to fit into the set-up. In addition, an Inconel part with a smooth surface has been machined from a forged Inconel-625 circular bar to serve as the baseline control condition.
Both CFD and experimental results were compared for different Reynolds numbers. The experimental results validated the CFD findings. Significant differences in the Nusselt numbers and pressure drops were observed across the different AM surfaces, with the surface with 90° build orientation performing best in terms of heat transfer. Based on these results, further investigation on the effects of 90° weld tracked surfaces in a circular form was also carried out. For this exploration, two aluminum (Al-6061) channels - one with a smooth surface and the other with internal threads serving as artificial waviness, similar to an AM surface with a 90° build orientation to the fluid flow direction - were conventionally manufactured and both CFD and experimental investigations were carried out for different mass flow rates. Both CFD and experimental results show that the artificial waviness (structured surfaces) has a significant impact on heat transfer and leads to a high cooling efficiency with a Nusselt number approximately 3x larger for various flow conditions compared to the smooth channel. However, the intentional structured surface also leads to larger pressure drops and may require extra pumping power, depending upon the application.