Thermal and structural performance of additively manufactured ceramic porous media burners

This study examines the effect of porosity, topology and material composition on the performance of additively manufactured ceramic porous media burners. Thermal-structural simulations of triply periodic minimal surfaces (TPMS) were performed to investigate thermal-stress magnitude and distribution. Alumina and mullite TPMS structures were 3D-printed and tested in a methane-air combustion experiment, where the mullite structures showed superior durability compared to alumina. X-ray imaging revealed notable correlation between predicted high tensile stress regions and experimental crack formation. At equivalent porosity and cell size, TPMS structures with higher specific surface area and tortuosity were found to have lower thermal strain and propensity for structural failure. Structures with these features, namely diamond and I-WP, demonstrated favorable thermal and structural behavior under identical thermal conditions. These findings can guide the design and manufacturing of high-temperature applications with embedded porous structures, such as heat exchangers, catalytic converters, and thermal management systems.