(H)olistic (A)pproach to the Design of Efficient Heat (R)ecovery Systems for Electrical (P)ower (P)roduction (HARP^2)

Lead Research Organisation: University of Huddersfield
Department Name: Sch of Computing and Engineering


Abstracts are not currently available in GtR for all funded research. This is normally because the abstract was not required at the time of proposal submission, but may be because it included sensitive information such as personal details.
Description 1. First demonstration of optimised 3D printed heat exchangers to be applied to acoustic engines. Initial designs printed in polymeric materials. Designs currently being developed for printing with minimal support systems with our collaborators Renishaw.

2. Complex single element heat exchangers components have been designed and printed and XCT quality assurance has been carried out in terms of geometry requirement (Dec/Jan 2020).

3. Further designs for exemplar regenerator parts have been completed and printed. The design called for the printing of lattice structures with varying levels of porosity and
lattice beam thickness. The parts are currently undergoing a series of X-ray Computer Tomography assessments to examine thier build consistency (Feb/Mar 2020). Following this assessment full mesh replacement parts can be printed and their efficacy verified.

4.In the, a new technique for designing surface texture on the CAD of lattices has been investigated and correlated with areal surface roughness parameters. After extracting areal surface parameters from the XCT data of the lattice, the method allowed for the design of this surface texture on the part CAD taking in consideration if its up skin or down skin, without using XCT data as the main input. By applying this method, it is possible to obtain a lattice CAD model with a designed surface texture and geometry that is more representative of the actual AM lattice. The mean deviation between the CAD model with the designed surface and the XCT was a third of the one between the XCT and the initial CAD. The proposed method allows for designing and replicating LPBF AM surfaces on the CAD of a lattice, taking into consideration the dimensional deviation caused by AM surfaces, especially on overhangs. Assuming that an LPBF AM process is stable and produces approximately the same AM surface, this method can be used to predict the geometry of a lattice, providing a cost-effective and efficient methodology that minimizes the time needed for design validation.
Exploitation Route 1. The basic principles developed here could be applied in several designs for acoustic engines and other heat exchangers for automotive and power applications
2. Design concepts completed could be applied to complex filter systems where single unit complex geometry filters are required
Sectors Chemicals,Energy,Manufacturing, including Industrial Biotechology

Description Collaboration of 3D metal printing 
Organisation Renishaw PLC
Country United Kingdom 
Sector Private 
PI Contribution Collaboration on the design an manufacture of heat exchanger
Collaborator Contribution Iteration of our design for heat exchangers which form part of our acoustic engines
Impact Designs for heat exchangers
Start Year 2018
Description In-Process Surface Metrology for Advanced Manufacturing Nov 2022 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Key note address at conference highlighting new developments in metrology for additive manufacturing
Year(s) Of Engagement Activity 2017,2019,2021
URL https://konferencja-pum.pollub.pl/en/
Description Keynote Address; 4th International Dental Congress Dahab Egypt Feb 2022 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact The application of additive manufacturing to patient specific dentistry and Maxillo facial surgery
Year(s) Of Engagement Activity 2022
Description MMN Measurement Strategy Event NPL (Zoom Meeting) 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Measurement Strategies for Additively manufaxctured part such as those produced in the HARP Project
Year(s) Of Engagement Activity 2020
URL https://www.npl.co.uk/
Description Presentation at National Physical Laboratory AM awareness meeting for industry 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Industry/Business
Results and Impact The presentation was designed around highlighting the scope of additive manufacturing primarily metal additive. The issues around print quality and quality assurance were highlighted. Case studies were presented such as those resulting from the HARP2 project
Year(s) Of Engagement Activity 2019