Highly Compact Metallic Heat Exchangers for Extreme Environments

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Project Term:
10/01/2020 - 03/31/2023

Critical Need:

Heat exchangers are critical to efficient thermal energy exchange in a variety of applications, including electricity generation, transportation, petrochemical processing, and waste heat recovery. Heat exchangers designed to handle ultra high pressures and high temperatures simultaneously would help to facilitate more efficient and cost effective thermochemical processes. However, the successful design of such devices is expected to require heat transfer surface and fin features that are too fine for current high temperature material manufacturing processes. Durable, reliable, and cost-effective higher temperature and pressure heat exchangers that exceed current operating conditions could reduce fuel consumption, system footprint, and capital cost while boosting the performance of a variety of power generation and industrial processes.

Project Innovation + Advantages:

The Boeing Company will develop a compact, extreme environment heat exchanger (EEHX) for application in supercritical carbon dioxide electric power generation cycles for hypersonic aircraft and land-based distributed power generation. Their metallic heat exchanger will be capable of operation at temperatures and pressures in excess of 1000°C (1832°F) and 80 bar (1160 psi), respectively. The team will design topologically optimized geometries and develop multifunctional, complex concentrated alloys that are expected to offer superior high temperature durability and thermal conductivity, as well as lower thermal expansion compared with state-of-the-art systems. The team will use advanced manufacturing approaches, including combinations of additive and subtractive manufacturing, powder metallurgy, superplastic forming, and solid-state bonding to fabricate the EEHX.

Potential Impact:

HITEMMP projects will enable a revolutionary new class of heat exchangers and innovative approaches to advanced manufacturing with applications for a wide range of commercial and industrial energy producers and consumers.


High performance, efficient heat exchangers would increase industrial productivity, supporting domestic industries. The developed manufacturing techniques for high temperature materials could strengthen U.S. leadership in advanced manufacturing.


More efficient electricity generation and industrial processes could significantly reduce emissions by enabling more efficient operations.


HITEMMP technologies could enable more cost-effective, efficient, and compact modular power generation systems for multiple applications.


ARPA-E Program Director:
Dr. David Tew
Project Contact:
Dr. Ali Yousefiani
Press and General Inquiries Email:
Project Contact Email:


University of Maryland
Allegheny Technologies Incorporated

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