An Integrated Laser Joining and Direct Fabrication Technique for Lightweight Titanium Heat Exchangers

"Triton Systems proposes to develop and characterize an advanced laser joining technique for titanium heat exchangers to provide lighter weight and lower cost heat exchangers while offering equivalent or better performance. Currently, heat exchangers arefabricated from stainless steel or inconel, which are heavy with a density of 6.6 g/cc (0.24 lb./cu.in.), so that weight-efficient designs are difficult to produce. For that reason, lighter weight materials that operate at high temperature are required forthe next generation of weapon systems, such as the F-35 Joint Strike Fighter. The density of titanium is 4.6 g/cc (0.17 lb./cu.in.), which is about 60% the weight of current stainless steel or inconel. However, before titanium can be fabricated intolightweight heat exchangers, a technique needs to be developed for providing reliable joining of thin, 0.004 to 0.020 inch (0.102 to 0.508 mm) thick, titanium for plate-fin heat exchangers. Triton's extensive experience in laser joining and depositionusing our patented Laser Free Form Fabrication (LF3TM) technique will be directly applied for obtaining an optimum joining technique for titanium heat exchangers. Triton is teamed with Northrop-Grumman and Hughes-Treitler, to adapt the LF3TM technology forjoining titanium materials for heat exchanger components. Triton's proposed joining method using the LF3TM technique for titanium heat exchangers will provide the Air Force with a lighter weig