Ultrasonic Additive Manufacturing for Capillary Heat Transfer Devices and Integrated Heat Exchangers

The goal of this program is to demonstrate the use of Ultrasonic Additive Manufacturing (UAM) to 3D print aluminum structural panels with integrated thermal management passages. This includes pumped integrated heat exchangers for fluid loops, integrated heat pipes, and integrated wick systems. By combining two functions (structure/thermal) it will be shown that a lighter weight, higher performance solution can be built in a shorter time period. The project team will demonstrate technical feasibility in Phase I. In Phase II the team will use UAM to 3D print an aluminum structure capable of carrying structural loads with integrated thermal management passages as may be used in a pumped integrated heat exchanger. This demonstration unit will be delivered to NASA for testing at the completion of the Phase II contract.