SAM4HeatPump

High-temperature heat pumps (HTWP) have been identified as one of the core technologies for the climate-neutral and efficient provision of industrial process heat and are intended to contribute to the decarbonisation of the EU (European Heat Pump Association (2023): Large heat pumps: the future-proof technology for the new industrial revolution). The key component here is the compressor. Due to their compact design and high power output, turbo centrifugal compressors are ideally suited. Research into increasing the efficiency of these machines is necessary in order to also increase the efficiency of HTWPs, as there is a direct proportionality between the two. In particular, the impellers of centrifugal compressors must be aerodynamically and structurally optimised to integrate the HTWP into the industrial process as required. Due to the parameterisation, the results of the computer-aided design are generally free-form geometries that are sometimes very difficult or impossible to implement using conventional manufacturing processes. Highly resilient materials that are energy-intensive to manufacture (titanium) are necessary to achieve high aerodynamic efficiency as a result of the mass and strength requirements. Their conventional processing chains are often complex and generate significant amounts of waste. The advantages of great design freedom, complemented by minimised waste volumes, make additive manufacturing processes extremely attractive. The aim of the research project is to sustainably produce heavy-duty impellers for turbocompressors in designs that are generated within a digital optimisation process chain and could therefore only be realised in part or not at all using conventional manufacturing processes. Additive manufacturing from metal powders, the Laser Powder Bed Fusion process (LBPF), is to be used for this purpose. The project is investigating the suitability of the process, characterising the material parameters and examining the use of new and recycled powder in terms of the circular economy.