Ducted heat exchanger sizing calculator

Sizes a radiator buried in a wing or fuselage, with its inlet diffuser and exit nozzle, for the lowest net cooling drag at the design flight condition. Duct drag and thrust follow F. W. Meredith’s momentum and heat-recovery analysis (ARC R&M 1683, 1935). Results update as you type.

ft
−5,000 to 104,987 ft
KTAS
Knots true
HP
–
ft/s
–
°F
Meredith assumed 125 °C (257 °F) glycol
Heat exchanger and duct assumptionsTypical values; open to change them

Core (tube or honeycomb matrix)

in
in

Ducting

deg
deg

Heat exchanger core, W × H × D

–in
–

Net cooling drag

–lbf
–

Cooling air mass flow

–lb/s
–

Inlet area

–in²
–

Inlet diffuser length

–in
–

Exit area and exit duct length

–in²
–

Side view, to scale

Heights and lengths in inches. Air flows left to right.

Side view of the inlet, diffuser, heat exchanger core and exit duct drawn to scale

Cooling air flow

Freestream Mach number–
Freestream dynamic pressure H–lbf/ft²
Ram temperature rise–°F
Coolant minus inlet air temperature–°F
Cooling air temperature rise–°F
Heat exchanger effectiveness ε–
Number of transfer units–
Velocity in the passages–ft/s
Passage Reynolds number –
Heat transfer surface area–ft²
Diffuser total-pressure loss–lbf/ft²
Core total-pressure loss h–lbf/ft²
  of which friction–lbf/ft²
  of which heating (momentum)–lbf/ft²
Total pressure behind core ÷ ambient–
Exit jet velocity–ft/s
Exit jet velocity ÷ flight speed–
Exit jet temperature–°F

Duct geometry

Inlet, width × height–in
Core face, width × height–in
Exit, width × height–in
Diffuser area ratio Aface/A1–
Exit contraction Aface/Ae–
Exit converging section–in
Exit parallel lip–in
Overall duct length–in
Freestream capture area–in²

Meredith (R&M 1683) cross-check

Loss ratio (h + hE)/H–
Duct efficiency ηd, eq. 11–
Cold drag power F·h(1 + h/4H), eq. 13–HP
Heat conversion efficiency ζ, eq. 22–%
Power recovered from heat, ζ·Q–HP
Net drag power, Meredith estimate–HP
Net drag power, this calculator–HP
Ram rise (V/100 mph)² °C, eq. 16–°F
Engine BHP if jacket heat = 0.46 BHP–BHP
Net drag power as % of that BHP–%

Performance at other speeds

Same altitude, temperature, coolant temperature and duct. “Fixed exit” keeps the design exit area, so the heat removed changes with speed. “Matched exit” resizes the exit (a cowl flap) to remove exactly the design heat load. Positive force is drag, negative is thrust.

Net cooling drag

Fixed exitMatched exit

Heat removed and exit area

Heat removed, fixed exit (% of design)Exit area for design heat (% of design)
Fixed exitMatched exit, same heat removed
KTASmphHeat removed, HP% of designFace velocity, ft/sNet drag, lbfExit area, in²Net drag, lbfDrag power, HP

Method

The inlet is assumed to sit clear of the boundary layer (a diverter or splitter plate), so the duct swallows freestream air at full total pressure; the heat exchanger adds no wetted area outside the airframe. Ram compression raises the cooling air to the freestream total temperature before it reaches the core, which is Meredith’s section 4.1 effect.

The core is a matrix of straight air passages with the coolant at one mean temperature. Heat transfer uses ε = 1 − e−NTU with Hausen’s developing-laminar Nusselt number below Re 2,300, Gnielinski’s with an entrance correction above 4,000, and a blend between. Friction uses Shah’s apparent friction factor (laminar) or Filonenko’s (turbulent), with the same entrance correction. Core total-pressure loss adds contraction and Borda–Carnot expansion at the passage ends and the momentum loss from heating the stream.

For each depth up to the maximum, the mass flow is whatever carries the heat load at that effectiveness, the face area follows from the face velocity, and the full duct is evaluated; the depth with the lowest net force is kept. Meredith notes (section 6) that minimum power falls near an air temperature rise of 85% of the initial difference, but that weight forces a lower figure in practice, which is what the maximum depth represents.

Net force follows Meredith’s momentum balance, D = ṁ(V − Ve) − (pe − p0)Ae, with the jet expanded from the total pressure and temperature behind the core to ambient pressure. Heat added at a pressure above ambient is partly turned back into jet momentum (eq. 22), which is how a well-designed duct reaches zero drag or net thrust at high speed. The cross-check table applies Meredith’s own closed-form equations to the same flows; his eq. 13 is incompressible and neglects nozzle losses, so expect the two net figures to differ by a few horsepower.

Diffuser length is the length at which walls diverging at the chosen half-angle reach the core face; the exit duct converges at its own half-angle and ends in a parallel lip half the exit height long, so the jet leaves parallel to the external stream as Meredith requires (section 6). Spillage, lip and external fairing drag are not included. Off-design points re-solve the mass flow so the inlet, core and fixed exit are all satisfied together; speeds where even a fully open exit can’t pass enough air are marked as out of reach.

This page was developed by Joe Wilding using AI. Contact me with questions or feedback on X: @joe_wilding