US20190039193A1 - Method for manufacturing a hybrid heat exchanger - Google Patents
Method for manufacturing a hybrid heat exchanger Download PDFInfo
- Publication number
- US20190039193A1 US20190039193A1 US16/158,143 US201816158143A US2019039193A1 US 20190039193 A1 US20190039193 A1 US 20190039193A1 US 201816158143 A US201816158143 A US 201816158143A US 2019039193 A1 US2019039193 A1 US 2019039193A1
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- US
- United States
- Prior art keywords
- header
- corrugated core
- heat exchanger
- powder
- top layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/26—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass heat exchangers or the like
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D53/00—Making other particular articles
- B21D53/02—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/60—Treatment of workpieces or articles after build-up
- B22F10/68—Cleaning or washing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
-
- B22F3/1055—
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D9/0031—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
- F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/02—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/02—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations
- F28F3/025—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being corrugated, plate-like elements
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/08—Elements constructed for building-up into stacks, e.g. capable of being taken apart for cleaning
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/08—Elements constructed for building-up into stacks, e.g. capable of being taken apart for cleaning
- F28F3/086—Elements constructed for building-up into stacks, e.g. capable of being taken apart for cleaning having one or more openings therein forming tubular heat-exchange passages
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F2005/005—Article surface comprising protrusions
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
- F28F2255/08—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes pressed; stamped; deep-drawn
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
- F28F2255/18—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes sintered
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
-
- Y02P10/295—
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4935—Heat exchanger or boiler making
- Y10T29/49389—Header or manifold making
Definitions
- the present disclosure relates to heat exchangers, more specifically to fin-type heat exchangers and methods of making such heat exchangers.
- the weak links in application of the current Laser Powder Bed Fusion (LPBF) technology to producing fin-type core heat exchangers is the limitation of achieving thin wall thickness and powder removal between tightly spaced fins.
- the wall thickness is primarily limited by dynamics of melting pool formation.
- the laser beam interaction with powder bed is controlled by laser energy density, which depends on beam diameter, laser power, scanning velocity, and powder characteristics.
- Experimental studies show limited success in achieving wall thickness less than 0.012 inches.
- certain applications can require wall thicknesses of 0.004 inches.
- Traditional methods to achieve such wall thickness with additive manufacturing resulted in microstructures with substantial voids and porosity.
- other traditional non-additive manufacturing methods utilize joining processes such as welding and brazing, which have limitations in terms of heat exchanger design space and process variation.
- a method for manufacturing a heat exchanger structure includes additively forming a top layer of a header after disposing a corrugated core within the header to retain the corrugated core within the header.
- Additively forming the top layer can include filling the corrugated core with powder until a suitable layer of powder overlays the corrugated core and the header and sintering the powder to form the top layer of the header.
- the method can further include additively forming a second header from the top layer.
- the method can further include disposing a second corrugated core within the second header.
- the method can further include additively forming a second top layer for the second header after disposing the second corrugated core within the second header to retain the corrugated core within the header.
- Additively forming the second top layer can include filling the second corrugated core with powder until a suitable layer of powder overlays the second corrugated core and the second header and sintering the powder to form the second top layer of the second header.
- the method can further include removing remaining powder from the corrugated core.
- Removing remaining powder from the corrugated core can include at least one of flushing, shaking, vacuuming, pressurizing, and/or a combination thereof.
- the method can further include placing the header on a build platform and placing a build plate around the header to retain the header and/or to maintain header shape during manufacturing.
- the method can further include placing a build plate around the second header to retain the second header and/or to maintain header shape during manufacturing.
- a heat exchanger structure can include an additively manufactured header defining a plurality of fluid channels therein and an opening, and a corrugated core defining flow channels therethrough and having a wall thickness of about less than or equal to 0.004 inches (about 0.1 mm), wherein the flow channels are disposed in fluid communication with the plurality of fluid channels.
- the corrugated core can be non-additively manufactured.
- FIG. 1 is a cross-sectional, perspective view of an embodiment of a heat exchanger structure in accordance with this disclosure
- FIG. 2 is a perspective view of an embodiment of a header disposed on a build platform
- FIG. 3 is a perspective view of the embodiment of a header as shown in FIG. 2 , showing a build plate disposed therearound;
- FIG. 4A is a perspective view of the embodiment of the header as shown in FIG. 2 , showing a corrugated core disposed therein;
- FIG. 4B is a cross-sectional, perspective view of the embodiment of FIG. 4A ;
- FIG. 5 is a perspective view showing an embodiment of a top layer forming a second header disposed over the corrugated core of FIG. 4A ;
- FIG. 6 is a cross-sectional, perspective view showing a second corrugated core disposed within the second header of FIG. 5 ;
- FIG. 7 is a cross-sectional, perspective view showing a top layer disposed over the second corrugated core of FIG. 6 .
- FIG. 1 an illustrative view of an embodiment of a heat exchanger structure in accordance with the disclosure is shown in FIG. 1 and is designated generally by reference character 100 .
- FIGS. 2-7 Other embodiments and/or aspects of this disclosure are shown in FIGS. 2-7 .
- the systems and methods described herein can be used to manufacture heat exchanger structures that include hybrid features.
- a method for manufacturing a heat exchanger structure 100 can include placing a header 101 on a build platform 103 .
- the header 101 can define a plurality of suitable fluid channels (not shown) therein and an opening 101 a .
- a build plate 105 can be placed around the header 101 to retain the header 101 and/or to maintain header shape during manufacturing.
- a corrugated core 107 can be disposed within the header 101 .
- the corrugated core 107 defines flow channels therethrough with a plurality of walls that define corrugations or any other suitable flow channels.
- the corrugated core 107 can include any suitable wall thickness (e.g., about less than or equal to 0.004 inches (about 0.1 mm)).
- the corrugated core 107 can be non-additively manufactured, which can allow for wall thicknesses below that which is achievable by traditional additive manufacturing processes.
- the flow channels of the corrugated core 107 are disposed in fluid communication with the plurality of fluid channels of the header 101 .
- a top layer 109 can be additively manufactured or otherwise manufactured on the header 101 after disposing a corrugated core 107 within the header 101 to retain the corrugated core 107 within the header 107 .
- Additively forming the top layer 109 can include filling the corrugated core 107 with a suitable powder (e.g., metal powder) until a suitable layer of powder overlays the corrugated core 107 and the header 101 .
- Additively forming the top layer 109 can also include sintering the powder to form the top layer 109 of the header 101 .
- the method can further include additively forming a second header 111 from the top layer 109 .
- the method can further include disposing a second corrugated core 115 within the second header 111 .
- the method can further include placing a build plate 113 around the second header 111 to retain the second header 111 and/or to maintain header shape during manufacturing.
- the method can further include additively forming a second top layer 117 for the second header 111 after disposing the second corrugated core 115 within the second header 111 to retain the corrugated core 115 within the second header 111 .
- the second top layer 117 can be additively formed by filling the second corrugated core 115 with a suitable powder until a suitable layer of powder overlays the second corrugated core 115 and the second header 111 , followed by sintering the powder to form the second top layer 117 of the second header 111 .
- the method can further include removing remaining powder from the first and/or second corrugated cores 107 , 115 at any suitable portion of the method.
- Removing remaining powder from the corrugated cores 107 , 115 can include at least one of flushing, shaking, vacuuming, pressurizing, and/or a combination thereof. Any other suitable method to remove remaining powder is contemplated herein.
- any suitable number and/or type of headers with any suitable number and/or type of corrugated cores can be made herein using any suitable method that includes embodiments (or any suitable portion thereof) of a method as described hereinabove.
- a single layer heat exchanger structure is contemplated herein.
- a plurality of layers e.g., two, three, four, etc. can be made including one or more layers manufactured using methods or portions thereof as described herein above.
- a heat exchanger structure 100 can be made to include an additively manufactured header 101 and a corrugated core 107 defining flow channels therethrough and having a wall thickness of about less than or equal to 0.004 inches (about 0.1 mm).
- the corrugated core 117 can be non-additively manufactured, thereby creating a hybrid heat exchanger structure 100 .
- the flow channels are disposed in fluid communication with the plurality of fluid channels.
- the heat exchanger structure 100 is shown as having two layers, the heat exchanger structure 100 can include any suitable number of layers.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Manufacturing & Machinery (AREA)
- Thermal Sciences (AREA)
- General Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Plasma & Fusion (AREA)
- Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
- Powder Metallurgy (AREA)
- Geometry (AREA)
Abstract
Description
- The present disclosure relates to heat exchangers, more specifically to fin-type heat exchangers and methods of making such heat exchangers.
- The weak links in application of the current Laser Powder Bed Fusion (LPBF) technology to producing fin-type core heat exchangers is the limitation of achieving thin wall thickness and powder removal between tightly spaced fins. The wall thickness is primarily limited by dynamics of melting pool formation. The laser beam interaction with powder bed is controlled by laser energy density, which depends on beam diameter, laser power, scanning velocity, and powder characteristics. Experimental studies show limited success in achieving wall thickness less than 0.012 inches. However, certain applications can require wall thicknesses of 0.004 inches. Traditional methods to achieve such wall thickness with additive manufacturing resulted in microstructures with substantial voids and porosity. However, other traditional non-additive manufacturing methods utilize joining processes such as welding and brazing, which have limitations in terms of heat exchanger design space and process variation.
- Such conventional methods and systems have generally been considered satisfactory for their intended purpose. However, there is still a need in the art for improved heat exchanger structures and methods of making heat exchangers. The present disclosure provides a solution for this need.
- A method for manufacturing a heat exchanger structure includes additively forming a top layer of a header after disposing a corrugated core within the header to retain the corrugated core within the header. Additively forming the top layer can include filling the corrugated core with powder until a suitable layer of powder overlays the corrugated core and the header and sintering the powder to form the top layer of the header.
- The method can further include additively forming a second header from the top layer. The method can further include disposing a second corrugated core within the second header. The method can further include additively forming a second top layer for the second header after disposing the second corrugated core within the second header to retain the corrugated core within the header.
- Additively forming the second top layer can include filling the second corrugated core with powder until a suitable layer of powder overlays the second corrugated core and the second header and sintering the powder to form the second top layer of the second header.
- The method can further include removing remaining powder from the corrugated core. Removing remaining powder from the corrugated core can include at least one of flushing, shaking, vacuuming, pressurizing, and/or a combination thereof.
- The method can further include placing the header on a build platform and placing a build plate around the header to retain the header and/or to maintain header shape during manufacturing. The method can further include placing a build plate around the second header to retain the second header and/or to maintain header shape during manufacturing.
- A heat exchanger structure can include an additively manufactured header defining a plurality of fluid channels therein and an opening, and a corrugated core defining flow channels therethrough and having a wall thickness of about less than or equal to 0.004 inches (about 0.1 mm), wherein the flow channels are disposed in fluid communication with the plurality of fluid channels. The corrugated core can be non-additively manufactured.
- These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description taken in conjunction with the drawings.
- So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, embodiments thereof will be described in detail herein below with reference to certain figures, wherein:
-
FIG. 1 is a cross-sectional, perspective view of an embodiment of a heat exchanger structure in accordance with this disclosure; -
FIG. 2 is a perspective view of an embodiment of a header disposed on a build platform; -
FIG. 3 is a perspective view of the embodiment of a header as shown inFIG. 2 , showing a build plate disposed therearound; -
FIG. 4A is a perspective view of the embodiment of the header as shown inFIG. 2 , showing a corrugated core disposed therein; -
FIG. 4B is a cross-sectional, perspective view of the embodiment ofFIG. 4A ; -
FIG. 5 is a perspective view showing an embodiment of a top layer forming a second header disposed over the corrugated core ofFIG. 4A ; -
FIG. 6 is a cross-sectional, perspective view showing a second corrugated core disposed within the second header ofFIG. 5 ; and -
FIG. 7 is a cross-sectional, perspective view showing a top layer disposed over the second corrugated core ofFIG. 6 . - Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, an illustrative view of an embodiment of a heat exchanger structure in accordance with the disclosure is shown in
FIG. 1 and is designated generally byreference character 100. Other embodiments and/or aspects of this disclosure are shown inFIGS. 2-7 . The systems and methods described herein can be used to manufacture heat exchanger structures that include hybrid features. - Referring to
FIGS. 1 and 2 , a method for manufacturing aheat exchanger structure 100 can include placing aheader 101 on abuild platform 103. Theheader 101 can define a plurality of suitable fluid channels (not shown) therein and an opening 101 a. Referring toFIG. 3 , in certain embodiments, abuild plate 105 can be placed around theheader 101 to retain theheader 101 and/or to maintain header shape during manufacturing. - Referring to
FIGS. 4A and 4B , acorrugated core 107 can be disposed within theheader 101. Thecorrugated core 107 defines flow channels therethrough with a plurality of walls that define corrugations or any other suitable flow channels. Thecorrugated core 107 can include any suitable wall thickness (e.g., about less than or equal to 0.004 inches (about 0.1 mm)). In certain embodiments, thecorrugated core 107 can be non-additively manufactured, which can allow for wall thicknesses below that which is achievable by traditional additive manufacturing processes. The flow channels of thecorrugated core 107 are disposed in fluid communication with the plurality of fluid channels of theheader 101. - Referring to
FIGS. 5 and 6 , atop layer 109 can be additively manufactured or otherwise manufactured on theheader 101 after disposing acorrugated core 107 within theheader 101 to retain thecorrugated core 107 within theheader 107. Additively forming thetop layer 109 can include filling thecorrugated core 107 with a suitable powder (e.g., metal powder) until a suitable layer of powder overlays thecorrugated core 107 and theheader 101. Additively forming thetop layer 109 can also include sintering the powder to form thetop layer 109 of theheader 101. - The method can further include additively forming a
second header 111 from thetop layer 109. In certain embodiments, the method can further include disposing a secondcorrugated core 115 within thesecond header 111. The method can further include placing abuild plate 113 around thesecond header 111 to retain thesecond header 111 and/or to maintain header shape during manufacturing. - Referring to
FIG. 7 , the method can further include additively forming asecond top layer 117 for thesecond header 111 after disposing the secondcorrugated core 115 within thesecond header 111 to retain thecorrugated core 115 within thesecond header 111. Similar totop layer 109, the secondtop layer 117 can be additively formed by filling the secondcorrugated core 115 with a suitable powder until a suitable layer of powder overlays the secondcorrugated core 115 and thesecond header 111, followed by sintering the powder to form the secondtop layer 117 of thesecond header 111. - The method can further include removing remaining powder from the first and/or second
corrugated cores corrugated cores - While the method as described above is shown as forming a
structure 100 including two layers, it is contemplated that any suitable number and/or type of headers with any suitable number and/or type of corrugated cores can be made herein using any suitable method that includes embodiments (or any suitable portion thereof) of a method as described hereinabove. For example, a single layer heat exchanger structure is contemplated herein. In other embodiments, a plurality of layers (e.g., two, three, four, etc.) can be made including one or more layers manufactured using methods or portions thereof as described herein above. - Using a method as described above, referring to
FIG. 1 , aheat exchanger structure 100 can be made to include an additively manufacturedheader 101 and acorrugated core 107 defining flow channels therethrough and having a wall thickness of about less than or equal to 0.004 inches (about 0.1 mm). Thecorrugated core 117 can be non-additively manufactured, thereby creating a hybridheat exchanger structure 100. The flow channels are disposed in fluid communication with the plurality of fluid channels. As described above, while theheat exchanger structure 100 is shown as having two layers, theheat exchanger structure 100 can include any suitable number of layers. - The methods and systems of the present disclosure, as described above and shown in the drawings, provide for hybrid heat exchanger structures with superior properties including the advantages of additive manufacturing (e.g., complex header channels and shapes) and the advantages of traditional manufacturing procedures (e.g., thinner corrugated core walls for higher efficiency). While the apparatus and methods of the subject disclosure have been shown and described with reference to embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the spirit and scope of the subject disclosure.
Claims (3)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US16/158,143 US20190039193A1 (en) | 2015-04-15 | 2018-10-11 | Method for manufacturing a hybrid heat exchanger |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US14/686,859 US10099325B2 (en) | 2015-04-15 | 2015-04-15 | Method for manufacturing a hybrid heat exchanger |
US16/158,143 US20190039193A1 (en) | 2015-04-15 | 2018-10-11 | Method for manufacturing a hybrid heat exchanger |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US14/686,859 Division US10099325B2 (en) | 2015-04-15 | 2015-04-15 | Method for manufacturing a hybrid heat exchanger |
Publications (1)
Publication Number | Publication Date |
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US20190039193A1 true US20190039193A1 (en) | 2019-02-07 |
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US14/686,859 Active 2036-11-26 US10099325B2 (en) | 2015-04-15 | 2015-04-15 | Method for manufacturing a hybrid heat exchanger |
US16/158,143 Abandoned US20190039193A1 (en) | 2015-04-15 | 2018-10-11 | Method for manufacturing a hybrid heat exchanger |
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US14/686,859 Active 2036-11-26 US10099325B2 (en) | 2015-04-15 | 2015-04-15 | Method for manufacturing a hybrid heat exchanger |
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GB (2) | GB2584969A (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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WO2022103917A1 (en) * | 2020-11-12 | 2022-05-19 | Raytheon Company | Method of making a cold plate with pre-formed fins using ultrasonic additive manufacturing; corresponding cold plate |
Families Citing this family (8)
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US10094628B1 (en) * | 2017-04-04 | 2018-10-09 | Hamilton Sundstrand Corporation | Heat exchanger |
CN110958924B (en) * | 2017-06-28 | 2022-09-13 | 艾威普科公司 | Additive manufactured heat exchanger header |
US10780632B2 (en) | 2017-06-28 | 2020-09-22 | Evapco, Inc. | Additive manufactured header for heat exchangers |
US11078795B2 (en) | 2017-11-16 | 2021-08-03 | General Electric Company | OGV electroformed heat exchangers |
US11365942B2 (en) | 2018-03-16 | 2022-06-21 | Hamilton Sundstrand Corporation | Integral heat exchanger mounts |
US20190285363A1 (en) * | 2018-03-16 | 2019-09-19 | Hamilton Sundstrand Corporation | Integral heat exchanger core reinforcement |
US20190383527A1 (en) * | 2018-06-13 | 2019-12-19 | Hamilton Sundstrand Corporation | Sublimator having integrally formed closure bars on a porous plate |
US11511346B2 (en) * | 2019-12-06 | 2022-11-29 | Hamilton Sundstrand Corporation | Hybrid manufacturing process for heat exchanger |
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US3713862A (en) * | 1970-11-16 | 1973-01-30 | Continental Can Co | Method for pigmented side striping of can bodies |
US3815535A (en) * | 1972-12-14 | 1974-06-11 | Schwaab W Lackfab Kg Inh Geb B | Apparatus and process for the making and coating of hollow bodies |
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JP2007178015A (en) * | 2005-12-27 | 2007-07-12 | Showa Denko Kk | Heat exchanger |
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JP5997590B2 (en) | 2012-11-15 | 2016-09-28 | 川崎重工業株式会社 | Heat exchanger and manufacturing method thereof |
US9952572B2 (en) | 2013-01-17 | 2018-04-24 | Bae Systems Plc | Object production using an additive manufacturing process |
US20140284038A1 (en) | 2013-03-21 | 2014-09-25 | Hamilton Sundstrand Corporation | Heat exchanger design and fabrication |
US20150137412A1 (en) | 2013-11-20 | 2015-05-21 | Carl Schalansky | Method of using additive materials for production of fluid flow channels |
CN105525992B (en) * | 2014-10-21 | 2020-04-14 | 联合工艺公司 | Additive manufactured ducted heat exchanger system with additive manufactured cowling |
US10830543B2 (en) * | 2015-02-06 | 2020-11-10 | Raytheon Technologies Corporation | Additively manufactured ducted heat exchanger system with additively manufactured header |
US10907500B2 (en) * | 2015-02-06 | 2021-02-02 | Raytheon Technologies Corporation | Heat exchanger system with spatially varied additively manufactured heat transfer surfaces |
-
2015
- 2015-04-15 US US14/686,859 patent/US10099325B2/en active Active
-
2016
- 2016-04-14 GB GB2012762.7A patent/GB2584969A/en not_active Withdrawn
- 2016-04-14 GB GB1606535.1A patent/GB2537503B/en active Active
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2018
- 2018-10-11 US US16/158,143 patent/US20190039193A1/en not_active Abandoned
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2022103917A1 (en) * | 2020-11-12 | 2022-05-19 | Raytheon Company | Method of making a cold plate with pre-formed fins using ultrasonic additive manufacturing; corresponding cold plate |
US11679445B2 (en) | 2020-11-12 | 2023-06-20 | Raytheon Company | Ultrasonic additive manufacturing of cold plates with pre-formed fins |
Also Published As
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US10099325B2 (en) | 2018-10-16 |
GB2584969A (en) | 2020-12-23 |
GB2537503B (en) | 2020-12-02 |
US20160305718A1 (en) | 2016-10-20 |
GB202012762D0 (en) | 2020-09-30 |
GB2537503A (en) | 2016-10-19 |
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