Topology Optimization of an Additively-Manufactured Heat Exchanger

Single liquid forced convection heat exchangers or cold plates have been investigated to keep automotive power electronics modules at optimal operating temperatures. Thermal-fluidic topology optimization (TO) is also becoming popular in realizing efficient microchannel heat sinks. Inspired by an interesting Puntozero design case study [1], this work presents a novel methodology that combines topology optimization and latticing techniques to obtain additive manufacturable high-performance heat sinks. A redesign process to replicate, adapt & optimize the existing design was first undertaken, geared at imbuing flow improvements while retaining heat dissipation performance. Thereafter, manufacturability assessments for AM took place to uncover necessary considerations for various design variants. Finally, design studies & performance characterization via CFD simulations were undertaken to gain insightful indices. Study findings indicate that the employment of two-dimensional topology optimization and lattice design strategies lead to better use of the design space. Conducted numerical investigations reveal better flow & thermal performance indices compared to baseline serpentine and replicated Punto zero cold plates ( less pressure drop, lower mean base temperature), evaluated at a baseline characteristic pumping power [2] ( ). Manufacturability indices are also encouraging, while the need for holistic workflows to bridge all aspects of the design process is identified and targeted for future development.

[1] nTop, (2023). Liquid-cooled cold plate for automotive power electronics

[2] Moreno, G., NREL (2020). Power Electronics Thermal Management.