This work presents the experimental results of a novel, air-to-air, additively manufactured manifold-microchannel heat exchanger with straight fins on both sides. The heat exchanger was made of Inconel 718 using a direct metal laser sintering technique. The overall core size of the heat exchanger was 94 mm × 87.6 mm × 94.4 mm, with a fin thickness of 0.220 mm on both the hot and cold sides. The heat exchanger was tested with pressurized nitrogen gas at 300 °C and 340 kPa for the hot side, while air at an ambient condition was used for the cold side. An overall heat transfer of 276 W/m²K was obtained for Reynolds number values of 132 and 79 for the cold and hot sides, respectively. A gravimetric heat transfer density (Q/m∆T) of 4.7–6.7 W/kgK and a volumetric heat transfer density (Q/V∆T) of 6.9–9.8 kW/m³K were recorded for this heat exchanger with a coefficient of performance value that varied from 42 to 52 over the operating conditions studied here. The experimental pressure drop results were within 10% of the numerical values, while the corresponding heat transfer results were within 17% of the numerical results, mainly due to imperfections in the fabrication process. Despite this penalty, the performance of the tested heat exchanger was superior to the conventional plate-fin heat exchangers: more than 60% of improvements in both gravimetric and volumetric heat transfer densities were recorded for the entire range of experimental data.

Compared to state-of-the-art heat exchangers, manifold-microchannel heat exchangers have shown superior heat removal density (kW/kg) at moderate pressure drops. However, manifold-microchannel heat exchangers made of Ni-based superalloys or other tough-to-machine materials can be a challenge to fabricate using conventional fabrication methods. This is mainly because of the inherently complex manifold microchannel geometry, as well as the required small feature sizes (e.g., fin thickness) that should be comparable, or smaller than state-of-the-art high-performance metallic-based heat exchangers (∼150 μm or smaller). In this study, a direct metal laser sintering (DMLS) additive manufacturing technique was used to fabricate the compact high-temperature manifold-microchannel heat exchanger reported here. The additively manufactured manifold-microchannel heat exchanger was fabricated as a single object, which significantly simplifies the fabrication process. In this work, three different additive manufacturing machines were used to study the effect of laser power, powder size, and layer thickness on the fin and channel sizes of the fabricated microchannel heat exchangers. To evaluate the minimum wall thickness for holding the required design pressures, pressure containment tests were performed. As a result, a wall thickness of 0.3 mm was shown to withstand 340 kPa and be leakage-free. A detailed analysis of different printing orientations and their effect on the manifold-microchannel heat exchanger's design was also performed. Finally, a 76 × 76 × 76 mm3 manifold microchannel heat exchanger was successfully fabricated with a fin thickness of 0.13 mm out of maraging steel. A second unit with dimensions of 94 × 87.6 × 94.4 mm3 was successfully fabricated with a fin thickness of 0.22 mm out of Inconel 718. Details of the fabrication process and key take-away results are discussed in this paper.