Fraunhofer Institute for Mechanics of Materials IWMThe ThermAl project developed innovative testing methods and service life models for aluminum components in heat exchangers. The goal is to reliably predict service life under realistic thermomechanical loads and thereby prevent failures.
Effects of thermally Induced Strains on the Service Life of Heavily Loaded Aluminum Components in Heat Exchangers
Completed research project
Project description
Market needs and challenges
Increasing demands on the reliability and service life of heat exchangers require robust methods for evaluating thermomechanical fatigue. SMEs, in particular, face the challenge of preventing component failures under realistic operating conditions while simultaneously reducing development times and costs.
Project approach
In the ThermAl project, novel test benches and experimental methods were developed to analyze the materials behavior of aluminum components under realistic thermomechanical loads. In addition, service life models and simulation tools were provided that enable an accurate prediction of component service life.
Contribution to addressing challenges
The project results enable industrial companies to specifically identify weak points and fully utilize service life reserves. The models and test procedures developed lay the foundation for improved product development, reduce testing efforts, and help minimize development risks at an early stage.
Fraunhofer IWM’s work packages in the project:
Fraunhofer IWM characterized materials behavior under isothermal and cyclic thermal stress, developed test benches, analyzed local microstructures, created and calibrated material models for simulations, and developed a comprehensive service life model for aluminum components. Finally, the models were validated, and a structured database was made available to industry partners.
Based on the project results, Fraunhofer IWM can offer industrial companies the following research and development services:
Development and calibration of service life models that enable companies to precisely predict the reliability of their components under real-world thermomechanical loads.
Conducting component-level tests using innovative test benches for a fast and cost-effective evaluation of new materials or manufacturing processes.
Adaptation and application of material models for FEM simulations to accurately predict the behavior of components under complex load combinations.
Damage analyses and fractographic investigations to specifically identify causes of failure and identify opportunities for optimization.
