Simulation of, Optimization of, and Experimentation with Small Heat Pipes Produced Using Selective Laser Melting...

Area of Science:

• Aerospace Engineering
• Materials Science
• Thermal Engineering

Background:

• Microsatellite technology generates increasing heat, demanding advanced thermal dissipation solutions.
• Metal powder additive manufacturing, specifically selective laser melting (SLM), enables customized, miniaturized heat pipes for small satellites.

Purpose of the Study:

• To design, simulate, optimize, and experimentally validate a small-scale heat pipe for enhanced thermal management in small satellites.
• To leverage SLM technology for creating tailored heat pipe solutions meeting specific mission requirements.

Main Methods:

• Heat pipe design and modeling using SolidWorks 2021.
• Finite element analysis (FEA) with ANSYS 2021R2 for thermal performance simulation.
• Multi-objective regression analysis for structural optimization.
• Fabrication via 3D printing (EOS M280) and experimental validation under vacuum conditions.

Main Results:

• Optimized heat pipe design showed a 10.5% reduction in thermal resistance and an 11.6% increase in equivalent thermal conductivity.
• Compared to conventional rods, the optimized heat pipe achieved a 38.5% decrease in thermal resistance and a 62.19% increase in thermal conductivity.
• Experimental tests indicated optimal performance at 20 W heating power, maximum capacity at 22 W, and an optimal fill ratio of 30%.

Conclusions:

• The SLM-fabricated heat pipe demonstrates excellent thermal performance and feasibility for small satellite applications.
• Selective laser melting technology offers a promising approach for developing advanced thermal management solutions in the aerospace industry.