Recent advancements in additive manufacturing (AM) have made it possible to create compact heat exchangers (HXs) with complex geometries. This study introduces a new approach that uses Triply Periodic Minimal Surface (TPMS)-based designs for HXs. Mathematical filtering techniques are incorporated to optimize the local morphology changes. The goal of the proposed mathematical filtering method is to improve the flow characteristics and heat exchange capability of TPMS HXs by modifying the structure’s morphology at the inlet and outlet regions. This modification facilitates flow selection and reduces pressure drop. The HX design includes cylindrical flow domains at the inlet and outlet regions. Three different HX designs with varying inlet/outlet domains (through-hole, half-hole, and taper-hole) were fabricated using polymer AM and DLP 3D printing. These designs were then tested for pressure drop. Among the three designs, the taper-hole configuration showed the best flow characteristics, with a 50% reduction in pressure drop compared to previous studies. The taper-hole design was then replicated using metal AM technology, resulting in a 70-125% improvement in heat exchange capacity compared to previous studies.

In this paper, the DSC and TGA for phenol and silica/phenolic composite were carried out by increasing temperature up to 950℃ with variable heating rate, to figure out basic thermal and pyrolysis characteristics of the composite. Also, the aim was to obtain the activation energy and the frequency factor which are the main parameters of the Arrhenius equation based on the Kissinger theory. The activation energy and frequency factor were used for the ablation model as material property. To confirm surface temperature distribution and recession of missiles, the CFD analysis using ANSYS Fluent R18.2 was performed to examine the thermal fluid characteristics of the hypersonic flight environment. Subsequently, the analysis results were applied as boundary conditions to a 2D axisymmetric pyrolysis and ablation model. Finally, pyrolysis and ablation analysis were performed using the ablation analysis code SAMCEF AMARYLLIS V.17, which uses the specific ablation module based on finite element code by applying carbon/phenolic and cork materials up to t = 10 s.