Jet fuel oxidation on metal additively manufactured tubes
Dipto, Mohammed Jubair
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https://hdl.handle.net/2142/124520
Description
Title
Jet fuel oxidation on metal additively manufactured tubes
Author(s)
Dipto, Mohammed Jubair
Issue Date
2024-04-15
Director of Research (if dissertation) or Advisor (if thesis)
Miljkovic, Nenad
Department of Study
Mechanical Sci & Engineering
Discipline
Mechanical Engineering
Degree Granting Institution
University of Illinois at Urbana-Champaign
Degree Name
M.S.
Degree Level
Thesis
Keyword(s)
Jet fuel
Additive Manufacturing
Coating
Abstract
In the aviation industry, jet fuel is used as a coolant as well as a propellant. At elevated temperatures, the jet fuel experiences significant thermal stresses, which leads to the oxidation of hydrocarbons when exposed to the heat exchanger walls. Undesirable insoluble carbon deposits on the internal walls impede the performance of the heat exchanger and the aircraft fuel system, compromising aircraft safety and performance. Here, we study the jet fuel fouling behavior on additively manufactured tubes created using stainless steel, aluminum, titanium, and Inconel, during autoxidation at high temperatures. Experiments were conducted using a fuel-fouling open loop system based on the Jet Fuel Thermal Oxidation Test (JFTOT). Scanning electron microscopy and characterization of the internal surface of the tubes showed that the jet fuel reacts differently with different metals and alloys. Comparisons were made with their traditionally manufactured counterparts and benchmarked with the performance of bare copper tubes. We show that additively manufactured tubes were more prone to fuel fouling due to the larger inherent roughness associated with the additive manufacturing process. We show that applying a thin layer of commercially available Silcolloy 2000 coating onto the internal surface minimizes jet fuel degradation significantly. Our work helps to enable the application of additive manufacturing for aircraft thermal management component manufacture by alleviating concerns related to fuel blockage stemming from surface deposition.
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