Computational and Experimental Investigation of Additively Manufactured Lattice Heat Sinks for Liquid-Cooling Railway Power Electronics

Ahmad Batikh (), Jean-Pierre Fradin and Antonio Castro Moreno
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Ahmad Batikh: Icam School of Engineering, Toulouse Campus, 31330 Toulouse, France
Jean-Pierre Fradin: Icam School of Engineering, Toulouse Campus, 31330 Toulouse, France
Antonio Castro Moreno: IRT Saint Exupéry, 31400 Toulouse, France

Energies, 2025, vol. 18, issue 14, 1-33

Abstract: This study investigates the performance of lattice-structured heat sinks based on BCCz unit cells in comparison to conventional straight-fin and pin-fin designs. Various lattice configurations were explored. Numerical simulations and experimental evaluations were carried out to analyze thermal resistance, pressure drop, and temperature distribution under different operating conditions. Among the designs, the BCCz configuration with a circular cross-section was identified as the most promising candidate for integration into the final heat sink demonstrator, offering reliable and consistent performance. A prototype using the BCCz lattice structure was additively manufactured, alongside a conventional design for comparison. The results highlight the superior heat dissipation capabilities of lattice structures, achieving up to a 100% improvement in thermal performance at high flow rates and up to 300% at low flow rates compared to a conventional straight-fin heat sink. However, the pressure drop generated by the lattice structures remains a challenge that must be addressed. This work underscores the potential of optimized lattice-based heat exchangers to meet the severe thermal management requirements of railway power electronics.

Keywords: additive manufacturing; lattice heat sink; railway power electronics; liquid cooling; CFD (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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