Integration of Thermal Managements Networks into Aluminium Structures by Stationary Shoulder Friction Stir Channelling
By Joao Gandra (TWI Ltd)

The present investigation demonstrates how a novel manufacturing process called Stationary Shoulder Friction Stir Channelling (SSFSC) can be used to integrate networks of cooling channels in metallic components. This technology was tested by processing AA6082-T6 and AA1050-H14 plates with a thickness of 15 and 20mm, respectively. The effect of the main processing parameters and tool geometry on channel cross section, microstructure and inner surface roughness was explored. SSFSC proved to be effective at controlling the channel cross-sectional consistency and a vastly improved as-processed surface finish. The area of the channels obtained varied between 5-40mm2. Flat and tubular heat exchanger demonstrators were successfully manufactured, featuring channels along linear, curved and helicoidal trajectories. Heat exchanger performance criteria were also tested namely leak testing, burst pressure, heat transfer and fluid flow pressure loss.