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SPIRITECH Advanced Products is a small business providing engineering services and technology development with a focus on intelligent integration of lightweight aerospace products that must survive harsh thermal and acoustic conditions.  We have many years of experience with aerodynamics, advanced cooling technologies, Computational Fluid Dynamics, thermal management, lightweight designs for extreme environments, static and dynamic structural analysis, propulsion system performance, combustion, vehicle integration, exotic materials, and high tech manufacturing techniques. We provide our customers a single source for research, analysis, design, test, development, fabrication, and system integration of flight components.

The SPIRITECH team is well versed in the design and manufacturing of hot, complex, lightweight aerospace structural components.  Due to our experience with severe thermal and vibratory design conditions of jet engine nozzles and afterburners (4000°F+, supersonic flow with flat panels vectored into the stream), SPIRITECH is well equipped to design components for the propulsion systems in subsonic, supersonic, and hypersonic vehicles.

SPIRITECH design and analysis capabilities span the various stages of the design from concept to production.  Throughout this range of development, SPIRITECH is capable of verifying the structural, aerodynamic, and thermal performance of our designs by sub-element, component, and large-scale testing.  Our engineers have performed tests that include coupon testing for material databases, sub-element structural testing, aero/thermal rig testing, mechanical kinematic/actuator rig testing, instrumentation definition, and data analysis.

SPIRITECH Advanced Products, Inc. is a pioneer in aerospace technology with a heritage stretching back more than 30 years. Our high tech skills, innovative thinking and world class leadership skills have been fine tuned by the highly competitive aerospace industry. SPIRITECH applies the experience gained in the aerospace industry to engineering services and product development for a wide array of industries.

About

Experts in Designing for Additive Manufacturing

SPIRITECH Advanced Products is pioneering a quantum shift in heat exchanger technology incorporating additive manufacturing, a fabrication method that relies on the process of adding material to make objects from digital 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.

As an early adopter of additive manufacturing, SPIRITECH Advanced Products is producing high performance heat exchangers unbounded by traditional fabrication methods. Large improvements are achieved, in part, by new technical benefits of integrating three-dimensional, multidisciplinary design features within the given volume and shape constraints. Large improvements in heat sink capacity are realized as heat exchangers are designed to fill the available volume. This is especially true in aircraft applications, where space is at a premium.

SPIRITECH-designed heat exchangers range in size from a small 1 inch x 2 inch to a size that completely fills the entire build volume of the EOS M400. SPIRITECH’s largest heat exchanger is among the world’s largest heat exchangers to be additively manufactured.

Experts in Heat Exchanger and Thermal System Design

SPIRITECH Advanced Products, Inc. has developed extensive background in heat exchanger and thermal management system design through 35+ years of aircraft propulsion design and analysis. Heat exchanger and thermal management design and development is performed using commercially available tools in conjunction with SPIRITECH’s specialized proprietary tools for modeling fluid and thermal systems.

The current state-of-the-art for heat exchanger analysis and design relies heavily on analytical approaches which are immature and highly empirical, thus making the ability to optimize advanced heat transfer devices improbable without comprehensive characterization efforts.  To address this problem, SPIRITECH has developed a multidisciplinary Heat Exchanger analytical tool for performing rapid thermal analysis and design optimization of advanced heat exchangers.  Heat exchanger characterization and scaling laws are incorporated in the model through application of fundamental physical equations and relationships to provide accurate scaling for geometry, configuration, installation effects, materials, working fluids, structural impacts, and manufacturing considerations.  Component templates are incorporated to allow construction of heat exchangers, including new concepts and advanced designs, providing the means to investigate potential candidate technologies and heat transfer mechanisms that can lead to improvements in heat exchanger volumetric efficiency over current technology while reducing the time frame from concept to finished product.  A multi-disciplinary approach is used to evaluate the interactions of the thermal analysis, working fluid flow analysis, and structural analysis to provide heat exchanger designs optimized for thermal performance, cost, volume, and weight

Engineering Outsourcing Specialists

SPIRITECH Advanced Products, Inc. is a pioneer in aerospace technology development with a heritage stretching back more than 30 years. Our high tech skills, innovative thinking, and world class leadership skills have been fine-tuned by the highly competitive aerospace industry. SPIRITECH applies the experience gained in the aerospace industry to engineering services and product development for a wide array of industries.

SPIRITECH‘s commitment to developing state of the art technologies, combined with years of experience operating at the highest level of engineering skill, produces unmatched attention to detail at all stages of a product’s life cycle. The result is delivery of affordable, timely, and innovative solutions that meet or exceed all of your project goals.

SPIRITECH offers a full range of services capable of catering to your industry’s needs. Our well-rounded experience includes:

  • Mechanical Design
  • Fluid Flow & Heat Transfer
  • Thermal Management
  • Aerodynamics and Computation Fluid Dynamics
  • Structural and Dynamic Finite Element Analysis
  • Combustion Physics and Chemistry Modeling
  • Transient & SS Propulsion System Performance Analysis
  • RCS & IR Design, Analysis, and Testing
  • Drafting and Solid Modeling
  • Exotic/Composite Material Design
  • Experiment/Testing Design and Support
  • Manufacturing (Process and Support)

AND ALWAYS……SPIRITECH’s “Above & Beyond” Customer Support

Additive Manufacturing

Designing for Additively Manufactured (AM) Heat Exchangers

SPIRITECH’s engineering team utilizes the latest thermal, structural analysis, and CFD tools to design cost-effective thermal solutions that meet or exceed customer requirements. Our mission is to find the ideal solution to your heat transfer problem. Our manufacturing engineering team integrates the best Design-for-Manufacturability (DFM) principals to ensure that affordability and performance goals are concurrently achieved.


SPIRITECH understands the challenges associated with designing for additive manufacturing and has developed processes and procedures to address design considerations:

  • Recoater-to-part interactions
  • Grow angles and laser-to-part interactions
  • Wall taper
  • Part removal from platform
  • Supports for growth of thin-walled features
  • Powder removal
  • Design feature exclusion
  • Post process machining
  • Cost reduction

Customizing AM Build Parameters

Current state of the art for additive manufacturing allows many typical parts to be fabricated using default build parameter settings. However, heat exchangers have very demanding requirements for thin walls and smooth flow surfaces that cannot be constructed using default settings. Rough surfaces may enhance heat transfer, but they do so at the cost of increasing pressure drop. The opposing design goals of minimizing pressure drop and maximizing heat transfer must be balanced. This requires development of build parameter sets that are conducive to achieving the heat exchanger’s design goals.

SPIRITECH has worked extensively to understand and optimize the AM build parameters for heat exchanger fabrication. These parameters include power, speed, offsets, and scan strategies, to name a few. Optimizing these parameters has been demonstrated by SPIRITECH to provide weight reductions approaching 50% and thermal effectiveness improvements greater than 10% relative to those achieved using default settings. In addition, optimized build parameters have also been effective at reducing fabrication times by 50% relative to build times achieved using default parameters.

SPIRITECH’s heat exchanger design-for-manufacturing philosophy extends to the process control of AM machine settings, scanning strategies, and powder selection.  The thin-walled, complex surfaces, and large surface area of additively manufactured heat exchangers require a unique set of AM process controls with application-dependent understanding of melt pool physics, cost sensitivity, AM machine dynamics, material property variability, and the relationship between as-design versus as-built geometry.  Optimized build parameters are defined to minimize flaws and optimize the material properties for thin-walled HX structures. 

SPIRITECH‘s expertise in designing for AM and defining optimum build parameters provides exceptional value to its customers.

Engineering Services

SPIRITECH Advanced Products, Inc. excels at providing superior engineering services at any stage of your product’s life cycle. Our experts will guide you through the iterative design process whether you’re just starting out with a new concept or you’re moving towards product realization.

Our Integrated Product Development Teams (IPT) have all the analytical tools and technical expertise necessary to make us a one-stop shop for your engineering services and product development needs. Performance, Aero/Thermal, Structures, and Design disciplines work fluidly together to optimize the iterative design process. Designs are critiqued meticulously by our Chief Engineers at strategic points during the project. Additionally, Gate Reviews evaluate technical content, ensuring that the customer receives the highest quality, value, and performance for their products.

At SPIRITECH, our experienced mechanical designers work closely with the other engineering disciplines at all stages of your product’s life cycle, ensuring realization of a low cost, optimized, and robust solution that meets or exceeds your design objectives.

Project Management

  • Single point of contact for all communication
  • Establish Earned Value Milestones and Report Project Status
  • Track Action Items and Ensure On-Time Completion
  • Document Decisions and Agreements through Coordination Memos
  • Ensure Strict Configuration Control through Established Procedures and Formalize through Interface Control Documents (ICD)
  • Provide Interim and Final Reports
  • Procure Hardware

Mechanical Design

  • Conceptual and/or Detailed Design Definition
  • Design of Low Cost Structures for Extreme Environments
  • Sophisticated Trade Study Techniques
  • Design Validation via Aerodynamic, Structural, and Thermal Analysis
  • Kinematic Design and Analysis
  • Hardware Definition
  • Advanced Materials and Processes
  • Advanced Manufacturing
  • Additive Manufacturing Specialists

Structural Analysis

  • Advanced Geometry FEA Modeling
  • Structural Approach Consistent with Design Maturity
  • Low/High Temperature Conventional Metals, Composites, and Polymers
  • Static Linear – Plasticity – Buckling
  • System Transient Analysis
  • Cyclic Failure Modes
  • Acoustic/ Dynamic High Cycle
  • Thermal/Mechanical Low Cycle
  • Modal, PSD, Harmonic Analysis
  • ANSYS Solutions Accelerated by Proprietary Macro Coding

Aerodynamics

  • High speed and low speed flows
  • Compressible and incompressible flows
  • Reacting flows
  • Boundary layer interactions
  • CFD analysis
  • SPIRITECH proprietary analysis tools

Flow and Thermal Analysis

  • Cooling System Design and Analysis
  • Steady State Thermal Analysis
  • Transient Thermal Analysis
  • Film Cooling Analysis
  • Fluid Network Modeling
  • Advanced Heat Exchanger Analysis
  • Boundary Condition Generation
  • Custom Software Development

Test Support

  • Test Hardware Design
  • Rig Design
  • Facility Integration
  • Installation
  • Data Acquisition
  • Test Execution

Manufacturing

SPIRITECH delivers finished parts and/or assemblies to the customer utilizing an extensive manufacturing network.

  • Manufacturing Involvement During Design Phase
  • Supplier Sourcing for Process Alignment
  • Progress Monitoring
  • Complex Forms from High Temperature and Exotic Metals
  • Composites
  • Final Assembly, Instrumentation, and Delivery

Research

AIAA-2010-7125: Incorporation of a Trade Study Tool for Fuels Development within SRHEAT™

A Scramjet/Ramjet Heat Exchanger Analysis Tool (SRHEAT™) has been developed for rapid analyses of complex thermal cooling systems. Thermal management is critical to the development of dual-mode scramjets for hypersonic aerospace propulsion, which have high thermal loading with limited availability of heat sink sources. It is necessary that rapid trade studies of the thermal management system be accomplished to optimize the system for weight and cooling efficiency. To meet this need, SPIRITECH has developed a scramjet/ramjet heat exchanger design and optimization tool that performs a thermal analysis of the heat exchanger, assesses its structural strength, and optimizes the heat exchanger design to minimize the cooling flow requirement and the heat exchanger weight. FuelDev™ has been developed as an add-on to SRHEAT™ to provide a system level tool allowing fuels developers to experiment with fuel databases and to perform “what if” scenarios to determine the system level impacts of changes in fuel properties. FuelDev™ provides a tool to compare and contrast existing fuels for use in hypersonic vehicle thermal management systems. This tool provides the user with the ability to quantify the sensitivity of the thermal management system to changes in fuel properties afforded by new fuel technologies. The detailed heat exchanger design features included in the tools (i.e. geometry, material properties, fuel/coolant properties, etc.) make SRHEAT™ and FuelDev™ a valuable suite of tools in scramjet and hypersonic vehicle development, providing the low cost analytical capabilities that make possible the efficient development of aerospace components and fuels.

AIAA-2010-6787: Material Development (MatDev™) Module for use with SPIRITECH’s Scramjet/Ramjet Heat Exchanger Analysis Tool (SRHEAT™)

A Material Development tool (MatDev™) has been developed as an add-on module to complement SPIRITECH Advanced Products, Inc’s existing Scramjet/Ramjet Heat Exchanger Analysis Tool (SRHEAT™).  SRHEAT™ is a scramjet/ramjet heat exchanger design and optimization tool that performs a thermal analysis of a heat exchanger, assesses its structural integrity, and optimizes the heat exchanger design to minimize the cooling flow requirement and the heat exchanger weight.  SRHEAT™ can be used to evaluate and design complex thermal cooling systems, like those found in dual-mode scramjets for hypersonic aerospace propulsion, that have high thermal loading with limited availability of heat sink sources.  MatDev™, in combination with SRHEAT™, is a trade study tool that is used to compare and contrast high temperature metal alloys and high temperature composites (i.e. CMC, C/SiC) in fuel cooled, heat exchanger liner panel design applications.  MatDev™ uses typical engineering stress calculations and formulations to assess non-traditional stresses, such as interlaminar tension, interlaminar shear, in-plane shear, and flexure.  These non-traditional calculations allow MatDev™ to accurately evaluate laminated, directional materials, such as high temperature composites.  MatDev™ provides detailed outputs summarizing the resulting stress, weight, optimum heat exchanger design, and cooling flow requirements to provide the user with critical insight into the key drivers of the heat exchanger system of interest.

AIAA-2010-6642: Thermal Management and Fuel System Model for TBCC Dynamic Simulation

A dynamic simulator is being developed to demonstrate all modes of supersonic operation, including mode transition, for a Turbine-Based Combined Cycle (TBCC) propulsion system. The High Mach Transient Engine Cycle Code (HiTECC) is a highly integrated simulation tool comprised of models for each of the TBCC systems whose performance and controllability affect the thrust and operability of the propulsion system. The reported work details the development of the Thermal Management and Fuel System model conducted in the second year of a multiyear effort to develop a dynamic TBCC simulator. Once completed, this model will significantly extend the state-of-the-art for all TBCC modes of operation by providing a numerical simulation of the systems, interactions, and transient responses affecting the ability of the propulsion system to transition from turbine-based to ramjet/scramjet-based propulsion.

AIAA-2010-6641: Hydraulic and Kinematic System Model for TBCC Dynamic Simulation

A dynamic simulator is being developed to demonstrate all modes of operation, including mode transition, for a Turbine-Based Combined Cycle (TBCC) propulsion system.  The High Mach Transient Engine Cycle Code (HiTECC) is a highly integrated simulation tool comprised of models for each of the TBCC systems whose performance and controllability affect the thrust and operability of the propulsion system. The reported work details the development of the Hydraulic and Kinematic System models conducted in the second year of a multiyear effort to develop a dynamic TBCC simulator. Once completed, this model will significantly extend the state-of-the-art for all TBCC modes of operation by providing a numerical simulation of the systems, interactions, and transient responses affecting the ability of the propulsion system to transition from turbine-based to ramjet/scramjet-based propulsion.

AIAA-2009-5298: Dual-Mode Scramjet Performance Model for TBCC Simulation

A Turbine-Based Combined Cycle (TBCC) dynamic simulation model is being developed to demonstrate all modes of operation, including mode transition, for a turbine-based combined cycle propulsion system. The High Mach Transient Engine Cycle Code (HiTECC) is a highly integrated tool comprised of modules for modeling each of the TBCC systems whose interactions and controllability affect the TBCC propulsion system thrust and operability during its modes of operation. By structuring the simulation modeling tools around the major TBCC functional modes of operation (Dry Turbojet, Afterburning Turbojet, Transition, and Dual Mode Scramjet) the TBCC mode transition and all necessary intermediate events over its entire mission may be developed, modeled, and validated. The reported work details the development of the gas turbine and dual-mode scramjet performance models conducted in the first year of a multiyear effort to develop a dynamic TBCC simulation model. Once completed, this model will significantly extend the state-of-the-art for all TBCC modes of operation by providing a numerical simulation of the systems, interactions, and transient responses affecting the ability of the propulsion system to transition from turbine-based to ramjet/scramjet-based propulsion while maintaining constant thrust.

AIAA-2009-5184: Scramjet/Ramjet Design and Integration Trade Studies Using SRHEAT™

The Scramjet/Ramjet Heat Exchanger Analysis Tool (SRHEAT) developed by SPIRITECH allows rapid analyses of the complex integrated cooling and structural systems required for hypersonic air-breathing propulsion systems. The ability to handle detailed heat exchanger and structural design features allows for near real time evaluation of performance and weight sensitivities to geometry, coolant path properties, flight conditions, construction materials, and fuels. These features make SRHEAT invaluable for initial assessment of hypersonic propulsion systems, providing the low cost analytical capability that makes rapid evaluation of design trade space possible. The ability to perform these trade studies as part of the early conceptual design phase is crucial to making correct initial design decisions before conducting more expensive preliminary and detail design efforts.  These broad capabilities of SRHEAT are illustrated with a series of example trade studies, showing how this tool can be used to insure selection of the best combination of geometry, thermal and structural designs, sizing, vehicle integration, and mission flight path.

AIAA-2008-5173: Systematic Optimization Approach for Scramjet/Ramjet Heat Exchanger Analysis Tool (SRHEAT™)

A Scramjet/Ramjet Heat Exchanger Analysis Tool (SRHEAT™) has been developed for rapid analyses of complex thermal cooling systems.  The detailed heat exchanger design features included in this code (i.e. geometry, material properties, fuel/coolant properties, etc.) make SRHEAT™ a valuable tool in scramjet and hypersonic vehicle development, providing the low cost analytical capabilities that make possible the efficient development of aerospace components. A key feature of SRHEAT™ is its ability to optimize the heat exchanger thermal design for minimum fuel flow requirement while providing a structurally viable design. Optimization includes both the ordering of the cooling flow circuit and the sizing of the heat exchanger channels. Large computational times are required for standard optimization techniques due to the sheer number of interdependent variables associated with the complex thermal management system. Several methods have been developed and adapted to reduce computational time requirements of optimization. The result is a fast code with the built-in intelligence to make design decisions leading to an optimized thermal management system design.

AIAA-2008-4614: Development of a Scramjet/Ramjet Heat Exchanger Analysis Tool (SRHEAT™)

A Scramjet/Ramjet Heat Exchanger Analysis Tool (SRHEAT™) has been developed for rapid analyses of complex thermal cooling systems.  Thermal management is critical to the development of dual-mode scramjets for hypersonic aerospace propulsion, which have high thermal loading with limited availability of heat sink sources. It is necessary that rapid trade studies of the thermal management system be accomplished to optimize the system for weight and cooling efficiency. To meet this need, SPIRITECH has developed a scramjet/ramjet heat exchanger design and optimization tool that performs a thermal analysis of the heat exchanger, assesses its structural strength, and optimizes the heat exchanger design to minimize the cooling flow requirement and the heat exchanger weight.  Radiation, conduction, and convection are all included to accurately model this complex aero/thermal system.  The user can select the coolant/fuel from various jet fuels (with endothermic properties)  or common combustible fluids (H2 & CH4).  In addition, the option for several high temperature materials are included. The code is packaged with a user-friendly interface to simplify its use within large trade studies. The detailed heat exchanger design features included in the code (i.e. geometry, material properties, fuel/coolant properties, etc.) make SRHEAT™ a valuable tool in scramjet and hypersonic vehicle development, providing the low cost analytical capabilities that make possible the efficient development of aerospace components.

AIAA-2006-0986: Thermal Analysis of Cooling Liners

A user-friendly heat transfer/thermal modeling code, LinerTherm™, has been developed for rapid analysis of aircraft exhaust liner cooling systems. Most of the thermal modeling codes on the market today fall into one of two categories either they are complex 3-D codes requiring significant engineering resources or they are simple conduction models that lack advanced convection capabilities required for high performance aerospace and propulsion cooling applications. In the high-tech field of aerospace propulsion, it is necessary that rapid modeling of complex thermal systems be accomplished to enable the trade studies required to optimize aircraft cooling liner designs for weight, cost, and performance. This code performs detailed thermal analysis of gas turbine exhaust liners used in the augmentor and nozzle and includes cooling capabilities for impingement, multi-hole film-cooled, slot filmcooled, and convectively cooled liners. Its simple user interface provides the capability of performing quick trade studies for a vast array of cooling liner designs, including a wide selection of included materials.

AIAA-2005-3501: FLUIDIC NOZZLE TO IMPROVE TRANSONIC PITCH AND THRUST PERFORMANCE OF HYPERSONIC VEHICLE

A study has been completed to evaluate the merits of using injection of high-pressure air to control a hypersonic vehicle s pitching moment without adversely impacting the installed nozzle performance. A 3D CFD model was developed and used to investigate the feasibility of using fluidic injection for vehicle control. The underlying critical parameters necessary to control the shock wave location were defined and their effects were quantified. Results have shown that variations in the injection pressure and flow provide changes in the oblique shock angle and that the pressures acting on the SERN ramp are increased in the region of the shock impingement on the ramp. The increase in pressure results in a corresponding change in vehicle moment. However, results have also shown that the resulting performance, when calculated as CFGsec=F/(Fidp+Fids), decreased as flow was injected, providing a net system loss. The parameters that may be used to control the angle of the oblique shock wave are the pressure, flow, and angle of injection flow. The pressure and flow were independently controlled in the matrix of CFD runs analyzed. The effect of pressure and flow on oblique shock angle are combined in the ideal thrust of the injectant (secondary) flow, which was found to be a critical correlating parameter. Although it is understood that the injection angle is also a critical parameter, its effects were not investigated in detail in this study.

AIAA-2004-3923: NOZZLE SELECTION AND DESIGN CRITERIA

Advances in aircraft performance depend heavily upon improved and properly integrated propulsion systems. Historically, new engines and aircraft are developed concurrently, but the design and test cycle of engine systems is longer than that of the aircraft they power because of demanding flight qualification, reliability, and durability requirements1. Consequently, the engine hardware development process starts first, so that the success of the entire program often hinges on engine design decisions made early in the process. Critical to the design of efficient air vehicle systems is the design of the gas turbine exhaust nozzle. Aircraft exhaust nozzles serve two primary functions. First, they must control the engine backpressure to provide the correct, and optimum, engine performance, which is accomplished through jet area variations. Second, they must efficiently convert the potential energy of the exhausting gas to kinetic energy by increasing the exhaust velocity, which is accomplished through efficiently expanding the exhausting gases to the ambient pressure. Since the exhaust nozzle provides the integration between the propulsion and aircraft systems, its design must also consider installed, or thrust minus-drag, performance. Additional design challenges are introduced by the requirement for features such as thrust vectoring and reversing. This paper provides guidelines and procedures for incorporating these considerations into the design of gas turbine exhaust nozzles.

AIAA-2004-3921: NOZZLE AFTBODY DRAG REDUCTION USING FLUIDICS

High transonic drag is an issue that must be considered in the design of supersonic flight vehicles. Generally, aftbody drag is maximum at flight Mach numbers near 1.0.  This study has shown numerically that fluidic injection can be used to decrease nozzle aftbody drag, thereby increasing nozzle performance under transonic conditions. The fluidic injection is used to separate the flow expanding over the external flap, increasing the static pressure and decreasing the aftbody drag. The amount of flow injected was identified as a critical performance parameter while injection pressure was found to have only secondary effects. Use of multiple injection locations provided greater drag reduction for a given amount of injection flow. However, the location of these injectors must be considered.

AIAA-2004-1212: FLOW TEST FOR PULSE DETONATION ENGINE

A test was conducted to measure the time-averaged flow rate of a pulse detonation engine. The objective of this flow test was to determine the flow effectiveness of a pulse detonation engine utilizing a rotating spool of tubes. Since thrust is directly proportional to flow, the ability of the device to pass flow at operating rotational speeds is critical to its ability to create thrust. The flow effectiveness at the interface between the statically mounted tubes and the rotating spool of tubes is driven by the time-varying open area of the tubes and the flow coefficient at the interface. This test measured the flow coefficient for variations in the time-varying open area at the interface resulting from various tube diameters and rotational speeds. While the rotational speed of the “detonation” tubes did affect the flow effectiveness at the tube/tube interface, the effect was minimal and does not limit the feasibility of a pulse detonation engine.