Additive Manufacturing Enables Liquid Hydrogen Heat Exchanger for Race Cars
Conflux Technology and Dallara are collaborating to develop an advanced liquid hydrogen-to-coolant heat exchanger for hydrogen-powered endurance race cars, leveraging additive manufacturing for complex geometries and thermal management.
Motorsport manufacturer Dallara is partnering with Conflux Technology to co-develop a sophisticated liquid hydrogen-to-coolant heat exchanger. This component is intended for a next-generation endurance race car that will utilize a hydrogen internal combustion engine (ICE).
A preliminary study program is currently in progress, with the primary objective of enabling liquid hydrogen-powered endurance racing. The collaboration aims to overcome the significant thermal management challenges associated with cryogenic temperatures. Both companies are employing additive manufacturing techniques to create intricate internal geometries, minimize risks of hydrogen embrittlement, and adapt the component to extremely confined spaces while meticulously controlling weight, thermal performance, and pressure drop.
This initiative aligns with the research activities supporting the Le Mans 24-hour race governing body’s hydrogen roadmap, which targets advancements towards 2030. The partnership positions Dallara to support manufacturers and top-tier racing teams exploring hydrogen-fueled endurance programs, capitalizing on Conflux's expertise in high-performance, additively manufactured heat exchangers.
Dallara is undertaking a pre-study of the critical subsystems for a liquid hydrogen storage and delivery system. This includes evaluating the impact at the vehicle level and constructing a digital twin of the complete system. The insights gained will furnish the necessary tools for developing a prototype endurance vehicle capable of competing in the hydrogen class, offering future manufacturers and team partners a validated technical foundation for hydrogen propulsion. The joint development specifically focuses on a hydrogen evaporator/heat exchanger designed to convert cryogenic liquid hydrogen from the tank into the gaseous state required for the injectors. The sizing and layout of this component are crucial, influencing pump selection, system packaging, overall mass, and integration with existing cooling loops, making it a foundational element of a liquid hydrogen propulsion architecture.
This collaboration highlights the critical role of additive manufacturing in enabling advanced propulsion systems for motorsport. By allowing for complex internal channels and precise thermal control in a compact, lightweight design, AM is crucial for overcoming the unique challenges of cryogenic liquid hydrogen in racing applications, pushing the boundaries of sustainable motorsport.
Edited by the news editor with AI from the original report — please refer to the original source.