飞行包线内空气换热器能力边界研究及进展

doi:10.7527/S1000-6893.2025.31745

Abstract

Abstract:

Understanding the heat transfer limits of heat exchangers for aero-engines within the flight envelope and expanding their performance boundaries are critical measures to advance aero-engines toward higher thrust-to-weight ratios. This paper focuses on the design requirements of heat exchangers used in cooled cooling air technology. First， the structures of typical air heat exchangers in aero-engines and novel heat exchanger structures with promising applications are reviewed. Then， the method for analyzing and expanding the performance boundaries of heat exchangers within the flight envelope is proposed to ensure the stable and efficient operation of the aero-engines under complex working conditions. The performance boundary range of non-uniformly arranged serpentine tube heat exchangers is also provided. Subsequently， the existing heat exchanger performance evaluation methods are reviewed， and the comprehensive performance evaluation plot for aero-engine heat exchangers is developed. Finally， the development prospects of air heat exchangers for aero-engines are discussed.

Key words: aero-engine, heat exchanger, flight envelope, performance evaluation, cooled cooling air

CLC Number:

V231.1

Yaling HE, Tao JIANG, Shen DU, Guoqiang XU. Research progress on performance boundary of air heat exchanger within flight envelope[J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(5): 531745.

Figures/Tables 8

Table 1

Experimental study of air heat exchanger

作者及年份	换热器类型	实验工况	换热器性能
Huang等^［24］2004	燃油-空气金属泡沫换热器	冷侧进口温度：700 K 热侧进口温度：922 K 冷侧质量流量：0.000 6 kg·s^-1	总热沉： 3 000.00~3 441.86 kJ·kg^-1
Wen等^［26］ 2017	燃油-空气管翅式换热器	热侧进口温度：423 K 冷侧质量流量：0.10~0.23 kg·s^-1 热侧质量流量：0.07~0.17 kg·s^-1	尺寸：268×72×80 mm³ 重量：1.207 kg 功重比：9.86 kW·kg^-1 换热量：11.9 kW
Li等^［11］ 2017	空气-空气蛇形管换热器	热侧进口温度：500 K 冷侧质量流量：0.10~0.60 kg·s^-1 热侧质量流量：0.05~0.20 kg·s^-1	尺寸：175×145×140 mm³ 重量：2.04 kg 热侧温差：200 K
Kim等^［13］ 2019	空气-空气U型平顶管式换热器	冷侧雷诺数：1 500 热侧雷诺数：10 200	冷侧温差：38.5 K 热侧温差：61.3 K 冷侧压降：1.41 kPa 热侧压降：43.48 kPa
Liu等^［27］ 2020	空气-空气板翅式换热器	冷侧进口温度：216.65~268.65 K 热侧进口温度：365.15~388.25 K 热侧质量流量：0.067 kg·s^-1	尺寸：180×180×86 mm³ 冷侧出口温度：291.45 K 热侧出口温度：299.65 K 冷侧压降：0.92 kPa 热侧压降：2.40 kPa
Ho等^［28］ 2020	多孔晶格空气换热器	功率：8 kW 冷侧质量流量：0.1~0.5 kg·s^-1 热侧体积流量：3.0 L·min^-1	冷侧换热系数： 75~300 W·m^-2·K^-1 多孔晶格换热器的换热系数是翅片管换热器的2倍以上
Broatch等^［29］2022	燃油-空气表面式换热器	热侧进口温度：1.33倍环境温度热侧体积流量：18.1×10^-3 m³·s^-1	换热系数： 314.1~942.9 W·m^-2·K^-1 阻力系数： 8.26×10^-3~21.69×10^-3
Pandey等^［30］2022	空气-空气交叉管式换热器	冷侧进口温度：953 K 热侧进口温度：1 023 K 冷侧质量流量：0.3~6.0 kg·s^-1 热侧质量流量：0.1~7.7 kg·s^-1	换热量： 193.74~205.38 kW 冷侧压降：5.5 kPa
Dixit等^［31］ 2022	三周期极小曲面换热器	冷侧进口温度：293 K 热侧进口温度：333 K 体积流量：100~270 mL·min^-1	尺寸： 32.2×32.2×32.2 mm³ 冷侧温差：10~14 K 热侧温差：13~20 K
Fu等^［32］ 2024	燃油-空气蛇形管换热器	冷侧进口温度：291~303 K 热侧进口温度：338~588 K 冷侧雷诺数：4 383~9 518 热侧雷诺数：1 100~13 225	换热量：16~28 kW 传热系数： 600~1 000 W·m^-1·K^-1

Table 1

Fig.1

Fig.2

Fig.3

Table 2

Fig.4

Fig.5

Fig.6

References 50

1	ZENG Q H， CHEN X W. Combustor technology of high temperature rise for aero engine［J］. Progress in Aerospace Sciences， 2023， 140： 100927.
2	WANG Y， DING X Y. Principles of aero engines［M］. Beijing： Beijing University of Aeronautics and Astronautics Press， 2009.
3	杨书杰. 新进展，新发现！“国家太空实验室”硕果频出！［EB/OL］. （2024-07-03）. .
	YANG S J. New progress and new discoveries！ The “National Space Laboratory” is yielding fruitful results！（2024-07-03）. （in Chinese）.
4	CHEN X Y， QIU L， ZHANG M S， et al. Nanoparticle-reinforced SiOC ceramic matrix composite films with structure gradient fabricated by inkjet printing and laser sintering［J］. Communications Materials， 2024， 5： 96.
5	ZHANG X F， DENG Z Q， LI H， et al. Al₂O₃-modified PS-PVD 7YSZ thermal barrier coatings for advanced gas-turbine engines［J］. NPJ Materials Degradation， 2020， 4： 31.
6	ZHUANG L H， XU G Q， LIU Q H， et al. Superiority analysis of the cooled cooling air technology for low bypass ratio aero-engine under typical flight mission［J］. Energy Conversion and Management， 2022， 259： 115510.
7	LIU P H， WANG R T， LIU S B， et al. Experimental study on the thermal-hydraulic performance of a tube-in-tube helical coil air-fuel heat exchanger for an aero-engine［J］. Energy， 2023， 267： 126626.
8	龚昊. 间冷回热涡扇发动机循环参数优化及间冷回热器设计方法研究［D］. 西安：西北工业大学， 2016.
	GONG H. Study on cycle parameter optimization for intercooled recuperated turbofan engine and design method for intercooler and recuperator［D］. Xi’an： Northwestern Polytechnical University， 2016 （in Chinese）.
9	CHEPKIN V. New generation of Russian aircraft engines conversion and future goals［C］∥International Symposium on Air Breathing Engines， 1999： 99-7042.
10	SOBEL D R， SPADACCINI L J. Hydrocarbon fuel cooling technologies for advanced propulsion［J］. Journal of Engineering for Gas Turbines and Power， 1997， 119（2）： 344-351.
11	LI H W， HUANG H R， XU G Q， et al. Performance analysis of a novel compact air-air heat exchanger for aircraft gas turbine engine using LMTD method［J］. Applied Thermal Engineering， 2017， 116： 445-455.
12	XU G Q， ZHUANG L H， DONG B S， et al. Optimization design with an advanced genetic algorithm for a compact air-air heat exchanger applied in aero engine‍［J］. International Journal of Heat and Mass Transfer， 2020， 158： 119952.
13	KIM J， SIBILLI T， HA M Y， et al. Compound porous media model for simulation of flat top U-tube compact heat exchanger［J］. International Journal of Heat and Mass Transfer， 2019， 138： 1029-1041.
14	刘启航，闻洁，吕璐璐，等. 紧凑翅片管式空气-燃油换热器试验［J］. 航空动力学报， 2023， 38（12）： 2848-2860.
	LIU Q H， WEN J， LV L L， et al. Experiment of compact finned-tube air-fuel heat exchanger［J］. Journal of Aerospace Power， 2023， 38（12）： 2848-2860 （in Chinese）.
15	E. U. 施林德尔. 换热器设计手册（第三卷）：换热器的热设计与流动设计［M］. 马庆芳，马重芳，译. 北京：机械工业出版社， 1988.
	SCHLUNDER E .U. Heat exchanger design handbook （Vol.3）： Thermal and hydraulic design of heat exchanger［M］. MA Q F， MA C F， trans. Beijing： China Machine Press， 1988 （in Chinese）.
16	LONDON A， SHAH R. Offset rectangular plate-fin surfaces： Heat transfer and flow friction characteristics［J］. Journal of Engineering for Power， 2013， 90： 218-228.
17	KAYS W M， LONDON A L， ECKERT E. Compact heat exchangers［M］‍∥Engineering， Materials Science， 1984.
18	DEWSON S J， GRADY C. Heatric™ workshop at MIT［D］. Boston： Massachusetts Institute of Technology， 2003.
19	FOCKE W W， ZACHARIADES J， OLIVIER I. The effect of the corrugation inclination angle on the thermohydraulic performance of plate heat exchangers［J］. International Journal of Heat and Mass Transfer， 1985， 28（8）： 1469-1479.
20	LI Q， FLAMANT G， YUAN X G， et al. Compact heat exchangers： A review and future applications for a new generation of high temperature solar receivers［J］. Renewable and Sustainable Energy Reviews， 2011， 15（9）： 4855-4875.
21	LI H， LIU H X， ZOU Z P. Experimental study and performance analysis of high-performance micro-channel heat exchanger for hypersonic precooled aero-engine［J］. Applied Thermal Engineering， 2021， 182： 116108.
22	SILVA R P P DA， MORTEAN M V V， DE PAIVA K V， et al. Thermal and hydrodynamic analysis of a compact heat exchanger produced by additive manufacturing［J］. Applied Thermal Engineering， 2021， 193： 116973.
23	ZHANG X， TIWARI R， SHOOSHTARI A H， et al. An additively manufactured metallic manifold-microchannel heat exchanger for high temperature applications［J］. Applied Thermal Engineering， 2018， 143： 899-908.
24	HUANG H， SPADACCINI L J， SOBEL D R. Fuel-cooled thermal management for advanced aeroengines［J］. Journal of Engineering for Gas Turbines and Power， 2004， 126（2）： 284-293.
25	冯博洋，于霄，吴小军，等. 基于石墨烯功能材料的高温钛合金多流体换热器研究［J］. 航空动力， 2024（2）： 61-64.
	FENG B Y， YU X， WU X J， et al. Study on high temperature titanium alloy multi-fluid heat exchanger based on graphene functional materials［J］. Aerospace Power， 2024（2）： 61-64 （in Chinese）.
26	WEN J， HUANG H R， LI H W， et al. Thermal and hydraulic performance of a compact plate finned tube air-fuel heat exchanger for aero-engine［J］. Applied Thermal Engineering， 2017， 126： 920-928.
27	LIU Z T， SUN M Y， HUANG Y Q， et al. Investigation of heat transfer characteristics of high-altitude intercooler for piston aero-engine based on multi-scale coupling method［J］. International Journal of Heat and Mass Transfer， 2020， 156： 119898.
28	HO J Y， LEONG K C， WONG T N. Additively-manufactured metallic porous lattice heat exchangers for air-side heat transfer enhancement［J］. International Journal of Heat and Mass Transfer， 2020， 150： 119262.
29	BROATCH A， OLMEDA P， GARCÍA-TÍSCAR J， et al. Experimental aerothermal characterization of surface air-cooled oil coolers for turbofan engines［J］. International Journal of Heat and Mass Transfer， 2022， 190： 122775.
30	PANDEY S， KALLATH H， CHOI H Y， et al. Numerical study of the effect of flow nonuniformities on the low-pressure side of a cooled cooling air heat exchanger［J］. Applied Thermal Engineering， 2022， 217： 119113.
31	DIXIT T， AL-HAJRI E， PAUL M C， et al. High performance， microarchitected， compact heat exchanger enabled by 3D printing［J］. Applied Thermal Engineering， 2022， 210： 118339.
32	FU Y C， BIAN B T， LIU Y L， et al. Airside heat transfer analysis using Wilson plot method of three analogous serpentine tube heat exchangers for aero-engine cooling［J］. Applied Thermal Engineering， 2024， 248： 123238.
33	LIU Q H， XU G Q， WEN J， et al. Multivariate design and analysis of aircraft heat exchanger under multiple working conditions within flight envelope［J］. Journal of Thermal Science and Engineering Applications， 2022， 14（6）： 061003.
34	谭公礼，吴学群，卢建. 机载换热器工作包线计算及试验研究［J］. 南京航空航天大学学报， 2019， 51（3）： 410-416.
	TAN G L， WU X Q， LU J. Calculation and experimental study on working envelope of airborne heat exchanger［J］. Journal of Nanjing University of Aeronautics & Astronautics， 2019， 51（3）： 410-416 （in Chinese）.
35	何雅玲，陶文铨. 强化单相对流换热的基本机制［J］. 机械工程学报， 2009， 45（3）： 27-38.
	HE Y L， TAO W Q. Fundamental mechanism of enhancing single-phase convective heat transfer［J］. Journal of Mechanical Engineering， 2009， 45（3）： 27-38 （in Chinese）.
36	何雅玲，雷勇刚，田丽亭，等. 高效低阻强化换热技术的三场协同性探讨［J］. 工程热物理学报， 2009， 30（11）： 1904-1906.
	HE Y L， LEI Y G， TIAN L T， et al. An analysis of three-field synergy on heat transfer augmentation with low penalty of pressure drop［J］. Journal of Engineering Thermophysics， 2009， 30（11）： 1904-1906 （in Chinese）.
37	何雅玲，陶文铨，王煜，等. 换热设备综合评价指标的研究进展［C］∥2011年中国工程热物理学会传热传质学学术会议. 北京：中国工程热物理学会， 2011.
	HE Y L， TAO W Q， WANG Y， et al. Research progress of comprehensive evaluation index of heat exchange equipment［C］∥Heat and Mass Transfer Conference of the Chinese Society of Engineering Thermophysics. Beijing：Chinese Society of Engineering Thermophysics， 2011 （in Chinese）.
38	HE Y L， TAO W Q. Numerical studies on the inherent interrelationship between field synergy principle and entransy dissipation extreme principle for enhancing convective heat transfer［J］. International Journal of Heat and Mass Transfer， 2014， 74： 196-205.
39	HE Y L， TAO W. Convective heat transfer enhancement： mechanisms， techniques， and performance evaluation［J］. Advances in Heat Transfer， 2017， 46： 87-186.
40	国家市场监督管理总局，国家标准化管理委员会. 制冷系统及热泵用换热器温度、压力和速度三场协同的性能测试和评价方法：［S］. 北京：中国标准出版社， 2022： 1-14.
	State Administration for Market Regulation， Standardization Administration of the People’s Republic of China. Heat exchanger for refrigerating systems and heat pumps-Performance test and evaluation method based on three-field synergy of temperature， pressure and velocity fields：［S］. Beijing： Standards Press of China， 2022： 1-14. （in Chinese）
41	TONG Z X， ZOU T T， JIANG T， et al. Investigation of field synergy principle for convective heat transfer with temperature-dependent fluid properties［J］. Case Studies in Thermal Engineering， 2023， 45： 102926.
42	TONG Z X， LI M J， DING Y. A field synergy principle of velocity and pressure for flow resistance reduction［J］. Journal of Enhanced Heat Transfer， 2022， 29（1）： 55-73.
43	陶文铨. 传热学［M］. 6版. 北京：高等教育出版社， 2024.
	TAO W Q. Heat transfer［M］. 6th ed. Beijing： Higher Education Press， 2024 （in Chinese）.
44	WEBB R L. Performance evaluation criteria for use of enhanced heat transfer surfaces in heat exchanger design［J］. International Journal of Heat and Mass Transfer， 1981， 24： 715-726.
45	BERGLES A E， BUNN R L， JUNKHAN G H. Extended performance evaluation criteria for enhanced heat transfer surfaces［J］. Letters Heat Mass Transfer， 1974， 1： 113-120.
46	LIU W， LIU Z C， MA L. Application of a multi-field synergy principle in the performance evaluation of convective heat transfer enhancement in a tube［J］. Chinese Science Bulletin， 2012， 57（13）： 1600-1607.
47	BEJAN A， PFISTER P A. Evaluation of heat transfer augmentation techniques based on their impact on entropy generation［J］. Letters in Heat and Mass Transfer， 1980， 7（2）： 97-106.
48	胡帼杰，过增元. 传热过程的效率［J］. 工程热物理学报， 2011， 32（6）： 1005-1008.
	HU G J， GUO Z Y. The efficiency of heat transfer process［J］. Journal of Engineering Thermophysics， 2011， 32（6）： 1005-1008 （in Chinese）.
49	FAN J F， DING W K， ZHANG J F， et al. A performance evaluation plot of enhanced heat transfer techniques oriented for energy-saving［J］. International Journal of Heat and Mass Transfer， 2009， 52（1-2）： 33-44.
50	JI W T， FAN J F， ZHAO C Y， et al. A revised performance evaluation method for energy saving effectiveness of heat transfer enhancement techniques［J］. International Journal of Heat and Mass Transfer， 2019， 138： 1142-1153.

几何参数	取值	几何参数	取值
管外径d_o/mm	4.0	横向节距s₁/mm	7.3
管壁厚度Δd/mm	0.3	纵向节距s₂/mm	6.4/5.6
空气流速u_c/（m·s^-1）	100.0	换热器高度H/mm	72.0
横向管排数量N_T	34	纵向管排数量N_L	16

[1]	Yiquan WU, Kang TONG. Research advances on deep learning-based small object detection in UAV aerial images [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(3): 30848-030848.
[2]	Xianzhao YANG, Gaowen LIU, Lingying GUO, Jiale MA, Aqiang LIN. Design of turbine high radius pre-swirl system with high temperature drop [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(2): 130672-130672.
[3]	Xinrui ZHANG, Zhi XIONG, Bing HUA, Jun KANG, Huiyu HE. A heterogeneous multi-source integrated navigation method for cross-domain vehicles based on inertial/celestial deep fusion [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(S1): 730614-730614.
[4]	Zeyong YIN, Gaiqi LI, Jiancheng SHI, Yueqian YIN. Concept, method and practice of advanced versatile core engine derivative [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(7): 29713-029713.
[5]	Xudong LUO, Yiquan WU, Jinlin CHEN. Research progress on deep learning methods for object detection and semantic segmentation in UAV aerial images [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(6): 28822-028822.
[6]	Boqing YAO, Jiayu CHEN, Changchao GU, Qinhua LU, Xuhang WANG, Hongjuan GE. A dynamic evaluation method for mission safety of missile equipment based on hierarchical safety control structure [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(6): 228858-228858.
[7]	Weina HUANG, Fangjuan LI, Hongbin QI. Preliminary investigation and thoughts on aero-engine digital engineering development [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(5): 529693-529693.
[8]	Ruixian MA, Xin WANG, Kaiming WANG, Bin LI, Mingfu LIAO, Siji WANG. Rubbing experimental study on labyrinth and rubber⁃coated case for aero⁃engines [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(4): 628350-628350.
[9]	Yuan XIAO, Kun FENG, Minghui HU, Zhinong JIANG. Extraction method for unsteady vibration components of aero-engine rotors [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(3): 228158-228158.
[10]	Zhe WANG, Zhiping WANG, Kunying DING, Tao ZHANG, Yuanhang WANG. Reliability analysis of thermal barrier coatings on turbine guide vanes of a certain type of aero-engine [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(22): 430141-430141.
[11]	Yingjie MEI, Dawei WANG, Chuanzhi SUN, Lamei YUAN, Xiaoming WANG, Yongmeng LIU. A digital twin testing and adjusting system for aero-engine casings based on augmented reality [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(21): 629462-629462.
[12]	Zesheng WANG, Hui WANG, Pengfei ZHANG, Lifeng DU, Hongqiang BAO, Dong LIN. Precision stacking assembly of aero-engine rotor driven by digital twin [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(21): 629759-629759.
[13]	Mingrui MA, Fuzhen CHEN, Hong YAN, Fan LIU. Numerical simulation of bird strike based on multi-resolution SPH-FEM coupling method [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(21): 230116-230116.
[14]	Jinyue LI, Pengfei ZHANG, Yuecheng GUO, Maocheng XU, Gang ZHAO. Assembly analysis of aero-engine mating interface based on digital twin [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(21): 629800-629800.
[15]	Fei TAO, Qingchao SUN, Huibin SUN, Xiaokai MU, He ZHANG, Lukai SONG, Jianqin ZHU, Zhi TAO. Aero-engine digital twin engineering: Connotation and key technologies [J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(21): 630283-630283.

Research progress on performance boundary of air heat exchanger within flight envelope

RichHTML

PDF (PC)

Knowledge

Abstract

Cite this article

share this article

Figures/Tables 8

References 50

Related Articles 15

Recommended Articles

Metrics

Comments