Abstract <p>This paper details the thermal design and the mechanical assessment procedures for an additively manufactured AlSi10Mg heat pipe, incorporating lattice structures as a wick for the cooling of a satellite power unit’s electronics. To optimize thermal performance, various lattice structures were experimentally investigated, focusing on properties, such as capillary rise, permeability, and heat removal capabilities. The best-performing lattice structure was further analyzed for its static and fatigue properties. A fatigue life model, comprising the experimental data on the lattice and SN diagrams for the bulk material obtained from propagation law, is presented. A sample representative of the heat pipe was designed and experimentally tested to validate the predictive capability of the fatigue life model and to assess the structural integrity of the heat pipe against the loading conditions experienced during a space launch. The heat pipe design demonstrated the ability to remove 24 W at 0<InlineEquation ID="IEq1"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="40964_2025_1111_Article_IEq1.gif" Format="GIF" Height="7" Rendition="HTML" Resolution="72" Type="Linedraw" Width="9" /> </InlineMediaObject> <EquationSource Format="TEX">$^\circ$</EquationSource> <EquationSource Format="MATHML"><math> <mmultiscripts> <mrow /> <mrow /> <mo>∘</mo> </mmultiscripts> </math></EquationSource> </InlineEquation> inclination, a near-isothermal functioning at 18 W up to an inclination of 15<InlineEquation ID="IEq2"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="40964_2025_1111_Article_IEq1.gif" Format="GIF" Height="7" Rendition="HTML" Resolution="72" Type="Linedraw" Width="9" /> </InlineMediaObject> <EquationSource Format="TEX">$^\circ$</EquationSource> <EquationSource Format="MATHML"><math> <mmultiscripts> <mrow /> <mrow /> <mo>∘</mo> </mmultiscripts> </math></EquationSource> </InlineEquation> angle, corresponding to a 34 mm height counter-gravity. The component demonstrated the capability to withstand the stresses resulting from nine repetitions of the space launch, confirming the model’s predicting capability. </p> Graphical abstract <p></p>

Comparative thermal analysis, design, and structural assessment of lattice-based additively manufactured heat pipes for space applications

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2025年5月12日

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Giovanni Brambati,
Luigi Vitali,
Manfredo Guilizzoni,
Emmanuel Caplanne,
Alfonso Niro,
Stefano Foletti

摘要

Abstract

This paper details the thermal design and the mechanical assessment procedures for an additively manufactured AlSi10Mg heat pipe, incorporating lattice structures as a wick for the cooling of a satellite power unit’s electronics. To optimize thermal performance, various lattice structures were experimentally investigated, focusing on properties, such as capillary rise, permeability, and heat removal capabilities. The best-performing lattice structure was further analyzed for its static and fatigue properties. A fatigue life model, comprising the experimental data on the lattice and SN diagrams for the bulk material obtained from propagation law, is presented. A sample representative of the heat pipe was designed and experimentally tested to validate the predictive capability of the fatigue life model and to assess the structural integrity of the heat pipe against the loading conditions experienced during a space launch. The heat pipe design demonstrated the ability to remove 24 W at 0 $^\circ$ $^{\circ}$ inclination, a near-isothermal functioning at 18 W up to an inclination of 15 $^\circ$ $^{\circ}$ angle, corresponding to a 34 mm height counter-gravity. The component demonstrated the capability to withstand the stresses resulting from nine repetitions of the space launch, confirming the model’s predicting capability.

Graphical abstract