In a groundbreaking development poised to revolutionize thermal management in aerospace and energy sectors, researchers from the State Key Laboratory of Material Processing and Die & Mold Technology at Huazhong University of Science and Technology have unveiled a novel approach to fabricating high-performance components. Led by Yi Li, the team’s work, published in the Journal of Materials Research and Technology (known in English as the Journal of Materials Research and Technology), combines advanced material composition and structural design to create components that could significantly enhance the efficiency and durability of thermal management systems.
The study focuses on the creation of triply periodic minimal surface (TPMS) lattice structures using oxide dispersion-strengthened CuCrZr alloy, a material known for its exceptional mechanical and thermal properties. By employing laser powder bed fusion (LPBF) technology, the researchers were able to fabricate structures with optimized performance characteristics.
One of the key innovations in this research is the systematic investigation of Y2O3 doping levels, ranging from 0 to 2.0 wt%, to determine their impact on the mechanical and thermal properties of CuCrZr composites. The findings revealed that a 0.5 wt% Y2O3 doping yielded the best overall performance, with a 16.2% improvement in room temperature ultimate tensile strength and an 8.11% increase in thermal conductivity compared to the undoped alloy.
“The enhanced mechanical properties are primarily due to the synergy of Y2O3-induced precipitation strengthening and grain refinement,” explained Yi Li, the lead author of the study. “The improved thermal conductivity, on the other hand, stems from reduced metallurgical defects and optimized heat conduction pathways.”
At the structural design level, the researchers evaluated four TPMS configurations—Gyroid, Diamond, Primitive, and I-WP—through a combination of experiments and simulations. The diamond lattice structure emerged as the top performer, exhibiting excellent thermal properties with a Nusselt number of 740.75 at a Reynolds number of 1445.5, and superior mechanical properties with an elastic modulus of 1127.53 MPa and a peak plateau stress of 18.67 MPa.
“The diamond lattice structure’s high specific surface area and tortuous flow channels enhance airflow disturbance, while its shear failure mode offers advantages in load-bearing capacity and energy absorption,” Li added.
The implications of this research for the energy sector are profound. High-load, high-efficiency components and lightweight, high-strength TPMS lattice structures could significantly improve the performance of thermal management systems in aerospace, power generation, and other energy-intensive industries. By integrating material composition and structural design, this optimization method paves the way for the development of next-generation components that can withstand extreme conditions and operate with unprecedented efficiency.
As the energy sector continues to evolve, the need for advanced materials and innovative design approaches becomes increasingly critical. This study, published in the Journal of Materials Research and Technology, not only addresses these needs but also sets a new benchmark for future research in the field. The work of Yi Li and his team at Huazhong University of Science and Technology represents a significant step forward in the quest for more efficient and reliable thermal management solutions.