- Monday, April 3, 2023
A next-generation aircraft engine heat exchanger will cut 1,000,000 tons of carbon emissions over a decade
The journey to a more sustainable aerospace industry
A new heat exchanger design was required for commercial aircraft engines, replacing existing models unable to provide sufficient cooling capability and creating drag in the engine.
Highly efficient cooling in hot weather conditions is critical, but the heat exchanger also must perform under cold conditions to avoid the engine oil congealing: a task easier to achieve with a larger, heavier exchanger, but at the cost of increased fuel consumption and carbon dioxide (CO2) emissions to compensate for reduced thrust.
Successful innovation through advanced prototyping and testing
AMETEK Hughes-Treitler is a leading provider of heat exchangers and thermal management solutions for aerospace and defense customers worldwide.
Experts in the research, development and delivery of customized solutions, Hughes-Treitler’s multi-stage design process includes on-site aerodynamics performance, thermal performance, stress, vibration, and fatigue testing. This ensures innovations can be developed and tested to the highest performance aerospace standards.
A streamlined design flies high
Heat exchangers use bypass air generated by the engine fan stage to remove very large amounts of heat from the engine. As the bypass air is what provides engine thrust, the exchanger needed to be as thin as possible to minimize thrust blockage and increase fuel efficiency; and as heat exchangers sit in the airflow of the engine, they are subject to potentially dangerous bird strikes or hail impacts - so the product needs to be tolerant to extreme stresses.
One million reasons to celebrate
AMETEK Hughes-Treitler global engineering teams utilized various AMETEK business system tools to efficiently design this new product including VOC and stage gate processes, producing prototype heat exchangers through additive manufacturing techniques. The result was a revolutionary design that provides an optimal mix of high heat dissipation, durability, light weight and small size - each a critical element in the design of aircraft components.
The new product has delivered considerable sustainability benefits. The thinner and more efficient design of the heat exchanger is estimated to lead directly to a reduction of approximately one million tons of carbon dioxide over a 10-year period. Driving such benefits aligns with AMETEK’s core value of social responsibility by using innovative solutions to help our customers create a more sustainable future. Discover more about Hughes Treitler.
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