Theory and experimental validation of cross-flow micro-channel heat exchanger module with reference to high Mach aircraft gas turbine engines

This study explores the design, analysis, and performance assessment of a new class of heat exchangers intended for high Mach aircraft gas turbine engines. Because the compressor air that is used to cool turbine blades and other components in a high Mach engine is itself too hot, aircraft fuel is needed to precool the compressor air, cooling is achieved with a new heat exchanger. The heat exchanger consists of a large number of miniature, closely-spaced modules. Within each module, the fuel flows through a series of parallel micro-channels, while the air flows externally over rows of short, straight fins perpendicular to the direction of fuel flow. A theoretical model was developed to predict the thermal performance of the module for various operating conditions. To confirm the accuracy of the model, a single module was constructed and tested using water to simulate the aircraft fuel. The theoretical model was used to predict the air temperature drop, water temperature rise, and heat transfer rate for each fluid stream. Comparisons between theory and experiment show good overall agreement in exit temperatures and heat transfer rates. This study shows the theoretical model is a reliable tool for predicting the performance of heat exchanger modules under actual fuel and air turbine engine conditions and for the design of aircraft heat exchangers of different sizes and design envelopes.