Surface Air-Cooled Oil Coolers (SACOCs) in Turbofan Engines: A Comprehensive Review of Design, Performance, and Optimization

Wiktor Hoffmann () and Magda Joachimiak
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Wiktor Hoffmann: Faculty of Environmental Engineering and Energy, Institute of Thermal Energy, Poznan University of Technology, 60-965 Poznań, Poland
Magda Joachimiak: Faculty of Environmental Engineering and Energy, Institute of Thermal Energy, Poznan University of Technology, 60-965 Poznań, Poland

Energies, 2025, vol. 18, issue 15, 1-13

Abstract: Surface Air-Cooled Oil Coolers (SACOCs) can become a critical component in managing the increasing thermal loads of modern turbofan engines. Installed within the bypass duct, SACOCs utilize high-mass flow bypass air for convective heat rejection, reducing reliance on traditional Fuel-Oil Heat Exchangers. This review explores SACOC design principles, integration challenges, aerodynamic impacts, and performance trade-offs. Emphasis is placed on the balance between thermal efficiency and aerodynamic penalties such as pressure drop and flow distortion. Experimental techniques, including wind tunnel testing, are discussed alongside numerical methods, and Conjugate Heat Transfer modeling. Presented studies mostly demonstrate the impact of fin geometry and placement on both heat transfer and drag. Optimization strategies and Additive Manufacturing techniques are also covered. SACOCs are positioned to play a central role in future propulsion systems, especially in ultra-high bypass ratio and hybrid-electric architectures, where traditional cooling strategies are insufficient. This review highlights current advancements, identifies limitations, and outlines research directions to enhance SACOC efficiency in aerospace applications.

Keywords: SACOC; heat-exchangers; geared turbofan engines; thermal management; aerodynamics (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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