Walter Ortiz, Shane Scott, Hidayah A Shukor, Shawn Clark EDSGN100 Section 00# Design Team Name and Design Team # Lockheed Martin Additive Manufacturing Walter Ortiz, Shane Scott, Hidayah A Shukor, Shawn Clark Purpose Our purpose is to design a new heat exchanger for additive manufacturing. Through additive manufacturing, we aspire to lower overall cost while improving efficiency of the heat exchanger. This poster will describe the change in price as well as what material we chose and our final design of the heat exchanger. Conclusion In conclusion, we have designed a more efficient, cheaper design that can be manufactured in less time than the original. The process is very effective and our chosen material is the best we have found. This new heat exchanger is almost guaranteed to perform better than the original. Project Description We chose the Lockheed Martin design project for a new heat exchanger created with additive manufacturing. Additive manufacturing allows us to design a heat exchanger with geometries that would be difficult to replicate otherwise. It makes it possible to lower overall cost, improve assembly time, and increased complexity of design geometry. Results We have chosen the Directed Energy Deposition method of manufacturing along with aluminum as our material of choice in manufacturing. Aluminum has a high thermal conductivity so we believed it would make a great material for our heat exchanger. For our design, we chose a zig-zag/ curved pattern for our internal fins. These increased the surface area per fin so that we could remove some of them, increasing airflow, decreasing mass and cost, and decreasing the time of manufacturing of the heat exchanger. This all makes the heat exchanger much more efficient. Figure 5 – Final heat exchanger design. Figure 1 – Original heat exchanger design. Acknowledgments (Calibri, 40 points, bold) We would like to thank Lockheed Martin for allowing us to participate in this project and show them our engineering abilities. Background Lockheed Martin is sponsoring a project to redesign a heat exchanger formerly manufactured using traditional subtractive processes. The new heat exchanger would utilize modern additive manufacturing processes. The process chosen specifically is the Directed Energy Deposition style. Directed Energy Deposition is a additive manufacturing process that is markedly similar to that of Gas Tungsten Arc Welding the difference being that instead of bonding two materials with filler material the filler material is instead layered upon itself. These new processes allow the design to take on more radical shapes which may lead to superior efficiency as well as reduced cost. References (Calibri, 40 points, bold) PennState_LM_Project_Listing v2. (n.d.). Retrieved April 25, 2016, from https://cms.psu.edu/section/default.asp?id=201516SPUP___REDS GN100_001 Lockheed Martin additive heat exchanger statement of work Lockheed Martin Presentation discussed in the Project Kick Off Meeting from 14 Mar 2016. (n.d.). Retrieved April 25, 2016, from https://cms.psu.edu/section/default.asp?id=201516SPUP___REDS GN100_001 Lockheed Martin Freshman Project kickoff Classifications of Heat Exchangers. R. K. Shah. Indian Institute of Technology Delhi. Retrieved on April 25, 2016. Retrieved from http://web.iitd.ac.in/~pmvs/courses/mel709/classification-hx.pdf Figure 4 – New heat exchanger geometric design. Professor Berezniak Spring 2016