10 May 2021
Airbus Exclusive Webinar: Modelling to support Thermal Management, Permeation and Integrity of Fuel Cells
TIME: 2pm CEST/1pm UK BST
Additive manufacturing (AM) is changing the design paradigm allowing the manufacturing of optimised shapes that were not possible before. Emerging, innovative ways of manufacturing heat exchangers are based on AM, and especially by powder bed fusion (PBF) processes. This process enables a step-change in the design of parts allowing for the creation of highly-tailored, complex geometries that could not otherwise be manufactured using conventional methods. From a thermal point of view, PBF can generate structures with exceptional surface area-to-volume ratios, critically with fully optimised fluid flow paths, that have the potential to enable highly efficient heat exchangers designs, without any additional manufacturing complexity.
Despite the huge design and manufacturing flexibility enabled by PBF there are challenges that need to be considered, especially when applying to hydrogen fuel cells technologies. Some examples are the presence of unavoidable manufacturing defects, variable surface roughness and hydrogen permeation issues.
Numerical modelling can help Design-for-AM by means of models that take into account the above challenges. Stochastic models based on experimental data are used to take into account manufacturing defects and predict thermal efficiency, pressure drops, temperature drops in heat exchangers. Similarly, permeation simulation are used to predict phenomena such as hydrogen embrittlement. Finally, the structural integrity of the fuel cell can be also predicted considering the effect of manufacturing defect on degraded mechanical properties due to hydrogen permeation.
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Meet the team
Senior Project Leader – Friction and Forge Processes
Kate has a degree in Materials Science and a Ph.D. in Structural Metallic Systems for Gas Turbine Applications from the University of Birmingham. Kate’s research was undertaken in collaboration with Rolls-Royce Plc and focused on friction welding of nickel super alloys.
Since joining TWI, Kate has led friction welding projects employing a variety of materials for a range of industrial applications. As well as working with clients to research and develop friction welding processes for novel applications, she also considers design for manufacture and joint integrity.
Mr Richard Freeman
Associate Director at TWI Limited
|Richard Freeman has also worked in the composites industry (Courtaulds) and served an apprenticeship in the steam turbine industry at NEI Parsons.
He obtained an honours degree in Metallurgy from Sheffield University in 1987, and a PhD in wear and corrosion resistant materials for aircraft actuation systems in 1994, while in full time employment with Lucas Aerospace.
Richard looks after the TWI customer base in the transport sector (aerospace and defence, automotive, rail and ship building) and sits on the AWS D17 committee for welding in the aerospace industry. He is TWI's representative on the Nadcap Welding Task Group, and also represents TWI on the Executive Committee of the UK Titanium Information Group and the UK Offset Strategy Group.
He assists TWI's Professional Division as the Professional Review Interviewer for MWeldI, SenMWeldI and CEng applications.
Dr Valerio Carollo
Senior Project Leader - Numerical Modelling and Optimisation
Valerio focuses his work on manufacturing process simulations and structural integrity analysis. In particular, his work has concentrated on fields such as Design-for-AM investigating lattice structures and their stochastic performances, AM simulations and joining process simulations for residual stress and distortions predictions, microstructure simulation for predictions of mechanical properties and hardness.
By background, Valerio is a NAFEMS Professional Simulation Engineer (PSE) in the field of thermo-mechanical behaviour of materials. He also hold a PhD in Computational Mechanics from IMT Lucca (Italy).