Design of multifunctional honeycomb materials

Extruded metal honeycombs [linear cellular alloys (LCAs)] are designed for a multifunctional application that demands not only structural performance but also heat transfer capabilities. The manufacturing process for LCAs enables complex in-plane cell topologies that may be tailored to achieve desired functionality. As a result, certain mechanical and heat transfer properties of LCAs are superior to those of hexagonal honeycombs or stochastic metal foams. Both periodic and functionally graded LCAs are designed for a structural heat transfer device for an electronic cooling application. The design problem is formulated as a multiobjective decision. Approximate models of structural and heat transfer performance, such as finite difference heat transfer simulations, are employed to analyze designs efficiently. A portfolio of heat exchanger designs is generated with both periodic and functionally graded cell topologies. Tradeoffs are assessed between thermal and structural performance. Previous authors have focused primarily on analysis of the structural and thermal properties of cellular materials; here, a,design perspective is adopted. Given a set of rigorous analytical models, the emphasis is on synthesis of cellular designs and identification of superior design regions.