Heat Transfer and Pressure Loss Performance of Additively Manufactured Metamaterials in Annular Channels

Emanuele Vaglio, Federico Scalzo, Marco Sortino and Luca Casarsa ()
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Emanuele Vaglio: Polytechnic Department of Engineering and Architecture, University of Udine, Via delle Scienze 206, 33100 Udine, Italy
Federico Scalzo: Polytechnic Department of Engineering and Architecture, University of Udine, Via delle Scienze 206, 33100 Udine, Italy
Marco Sortino: Polytechnic Department of Engineering and Architecture, University of Udine, Via delle Scienze 206, 33100 Udine, Italy
Luca Casarsa: Polytechnic Department of Engineering and Architecture, University of Udine, Via delle Scienze 206, 33100 Udine, Italy

Energies, 2025, vol. 18, issue 10, 1-19

Abstract: Additive manufacturing is revolutionizing the production of thermo-fluidic devices by enabling the creation of a wide variety of complex architectures, significantly enhancing performance and efficiency. Nevertheless, the range of structural types investigated to date remains limited, with most studies employing simplified methodologies and constrained operating conditions. This study explores the thermo-hydraulic performance of water-cooled annular channels incorporating BCC, Octahedral, and gyroid structures fabricated from AISI 316L stainless steel using Laser Powder Bed Fusion. The samples were experimentally tested across a broad spectrum of mass flow rates using a custom-designed test rig to evaluate heat transfer and pressure loss performance, and extensive morphological characterization was conducted to correlate the thermo-fluid dynamic behavior with the geometric and surface features specific to the manufacturing process. The investigation revealed that reticular configurations are preferable when low pressure losses are required, whereas gyroids are more suitable for high thermal loads. The topology of the structures was shown to be a key factor influencing overall performance, emphasizing the importance of selecting the appropriate structure for each specific application and the significant potential for performance improvements through the development of tailored metamaterials.

Keywords: laser powder bed fusion; additive manufacturing; cooling annular channel; metamaterials; heat transfer; pressure losses (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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