Integrating Thermal Management Networks in Structures by Friction

Stir Channelling

JOINT INDUSTRY
PROJECT OUTLINE

PROP305266

Summary

Thermal management is a critical area in the development of future transport systems.

Heat generation in vehicles is increasing due to the expansion of electronic functionality.
In parallel, the demand for more powerful propulsion systems is often limited by the ability
to dissipate waste heat without resorting to extra complexity and mass. This is driving a
demand for new approaches to thermal management. Heat transfer solutions are required
to be more efficient, compact and lighter, while remaining cost-effective.

Stationary Shoulder Friction Stir Channelling (SSFSC) is an innovative solid-state process

for integrating sub-surface networks in aluminium structures. One of the most promising
industrial applications is the manufacture of heat exchangers. The feasibility of the process
was already demonstrated during two internal exploratory projects, placing the Technology
Readiness at Level 3.

This Joint Industry Project will produce and test industrially relevant technology
demonstrators, defined by Sponsors. These will be benchmarked against mainstream
manufacturing processes, focusing mainly on productivity, flexibility, energy consumption,
cost and ability to simplify product design.

TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, United Kingdom. Tel: +44 (0)1223 899000
Integrating Thermal Management Networks in Structures by Friction Stir
Channelling

Project Concept

Motivation

Thermal management is a critical area in the development of future transport systems. Heat generation in vehicles
is increasing due to the expansion of electronic functionality. In parallel, the demand for more powerful propulsion
systems is often limited by the ability to dissipate waste heat without resorting to extra complexity and mass.

The growing trend of transport electrification introduces specific thermal management challenges. Improving
vehicle speed, autonomy and charging rates typically involves passing higher currents through the system. The
increase of current results in a quadratic growth of joule heating in the conducting elements of battery packs,
power electronics, motors and charging units. Excessive overheating is one of the main factors leading to battery
de-rating and decrease in vehicle performance.

From a structural perspective, vehicle body fabrication will increasingly rely on composite materials, most likely
in combination with metals. Composite materials have a greater temperature sensitivity relative to traditional
metallic designs. Joints between composites and metals suffer when subjected to mismatches in thermal
expansion. Military transport faces the additional challenges of needing to reduce heat signatures and dissipating
heat from weapon systems.

All these factors combined are driving a demand for new approaches to thermal management. Heat transfer
solutions are required to be more efficient, compact and lighter, while remaining cost-effective.

Friction Stir Channelling

Friction Stir Channelling (FSC) is an innovative solid-state

process for integrating sub-surface networks in aluminium
structures. One of the most promising industrial applications is
the manufacture of heat exchangers. The first studies reported
in the literature focused on using an approach similar to that of
Friction Stir Welding (FSW), i.e. deliberately promoting poor
material consolidation conditions to produce a continuous void
along the tool path. However, despite its great potential, this
technology has not yet been adopted by industry, mainly as a
result of not fulfilling the required repeatability, surface finish or
design flexibility.

A new approach

TWI has invented and patented a new Stationary Shoulder SSFSW process fundamentals
variant of FSC (SSFSC) which has proven to overcome many of
the drawbacks reported in literature. The stationary shoulder
confines the viscoplastic material region, limiting the flow of
material extracted from the workpiece. The feasibility of the
process was already demonstrated at TWI in two internal
exploratory projects, placing the technology readiness at level 3
(according to the TRL scale). AA6082-T6 and AA1050-H14
plates have been successfully processed, with a thickness of 5,
15 and 20mm. Flat and tubular demonstrators were successfully
manufactured, featuring channels along linear, curved and
helical trajectories.

Project aim Processing of a tubular component in AA6082-T6

TWI plans to conduct a Joint Industry Project to further mature SSFSW towards TRL 4, i.e. assess the performance
of realistic prototypes in laboratory conditions. The sponsors will provide essential guidance to define a selected
number of prototypes for each potential industrial application. Some of the potential thermal management
applications identified include:

 Integration of heat dissipation networks in busbars and housings for battery cell modules.

 Production of electric vehicle battery trays featuring integral cooling channels, as an alternative to the
conventional approach relying on accessory pipework.

TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, United Kingdom. Tel: +44 (0)1223 899000
Integrating Thermal Management Networks in Structures by Friction Stir
Channelling

 Integration of active cooling in casings for electric motors.

 Addition of heat dissipation networks to jet engine nacelles or

turbine casings.

 Production of anti-icing features on wings and flight control

surfaces for aircraft.

 Reducing heat signature of vehicle bodies.

 Active cooling of data servers, communication infrastructure or

radar installations.

Other potential applications have also been identified:

 Networks for lubrication or hydraulics

Cooling plate demonstrator
 Weight-reduction technique (manufacture of hollow panels or
lightweight structures).

 Embedding instrumentation (structural health monitoring or

communication).

Objectives

 Explore the use of SSFSC to process substrates with a

thickness between 2 and 5mm in 1xxx, 2xxx, 6xxx and 7xxx
series aluminium, as well as in copper alloys.

 Develop the technology for use with both gantry and robot
equipment.
Infrared thermal imaging evidencing circulation
 Define guidelines for FSC tool design for different materials. of liquid coolant through heated plate
demonstrator
 Establish preliminary product design criteria, namely channel
size range, aspect ratio, distance to surface and minimum
distance between adjacent channels.

 Produce and test industrially relevant technology demonstrators.

 Benchmark against mainstream manufacturing processes, focusing mainly on productivity, flexibility, energy
consumption, cost and ability to simplify product design.

Benefits for Sponsors

OEMs and Tier 1 suppliers

 Access to a new disruptive manufacturing process. Favourable access rights under patents.

 Possibility of tailoring the development of SSFSC to immediate requirements.

 The technical and economic data generated can be used to support future product development.

Equipment, consumable and material suppliers

 Assess if current portfolio of solutions is suitable for SSFSC.

 Gather information to develop new offering specifically for SSFSC.

Approach

Task 1 – Fundamental process development (Year 1)

 Explore a process window for SSFSC flat substrates with a thickness between 2 and 5mm in 1xxx, 2xxx,
6xxx and 7xxx series aluminium, as well as in copper alloys.

Copyright © TWI Ltd 2019

Integrating Thermal Management Networks in Structures by Friction Stir
Channelling

 Investigate the effect of tool geometry on channel geometry and inner surface roughness.

 Characterise the metallurgical and mechanical properties of the processed regions (tensile, bending and
burst testing).

 Assess post processing techniques to improve channel inner surface finish, e.g. abrasive flow machining.

 Quantify pressure loss and heat exchanger efficiency for linear channel segments.

 Test minimum cornering radius and spacing between adjacent channels when producing serpentine paths.

 Investigate the possibility of intersecting channel paths or overlapping channels at different depths.

 Investigate the possibility of varying channel dimensions or depth by varying the process parameters or
probe length in-situ.

 Explore advanced process control methods (temperature, torque and force control).

Task 2 – Industrial prototyping (Year 2)

 Liaise with the Sponsors to design and manufacture up to three technology demonstrators.

 Assess each technology demonstrator in terms of:

 Channel area dimensional and geometrical consistency.
 Pressure loss.
 Leak testing and pressurisation at envisaged operating pressures.
 Heat exchanger efficiency.

 Technical and economic benchmarking against applicable mainstream processes:

 Hydro-formed heat exchangers (e.g. ultrasonic welding, brazing or fusion welding foils onto plates
and using hydroforming to expand the cooling network).
 Brazing pipes onto structures.
 Extruded cool plates.
 Casting.
 Machined from solid, followed by welding or mechanical fastening a lid.
 Additive manufacturing.

 Undertake SSFSW trials using equipment owned by the Sponsors. This might be of particular interest to FSW
equipment suppliers seeking to demonstrate that their current product portfolio is suitable for SSFSC.

Deliverables

A final report will be issued at the end of each task, summarising all the work undertaken. One technology
demonstrator will be supplied to each sponsor at the end of Task 2. The Sponsors are welcome to witness SSFSC
trials at TWI. After some initial preliminary experiments, TWI will schedule a demonstration day for familiarisation
with the welding machines and procedures.

Price and Duration

The overall estimated price for the work is £250,000 (excluding VAT), which requires £25,000 per company per
annum for 2 years (£50,000 total) from each of five Sponsors. It is anticipated that the project will commence
with an agreed scope of work with a minimum of four Sponsors.

Further Information

For further information on how a Joint Industry Project (JIP) runs please visit:
http://www.twi-global.com/services/research-and-consultancy/joint-industry-projects/

JIP Co-ordinator: Tracey Stocks Email: jip@twi.co.uk

Project Leader: João Gandra Email: joao.gandra@twi.co.uk

TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, United Kingdom. Tel: +44 (0)1223 899000