Abstract: There is provided a heat exchanger comprising: a conduit defining an inlet flow path for a fluid; a header disposed to receive a flow from the inlet flow path; a heat exchanger matrix disposed to receive a flow from the header; and a swirler disposed within the conduit and the header. The swirler is arranged to disperse a flow from the inlet flow path over the heat exchanger matrix. The conduit, header, and swirler are formed as a unitary piece by additive manufacturing.

Abstract: A heat exchanger includes a conduit, a header, and a swirler been formed as a unitary piece by additive manufacturing. The swirler is disposed within the conduit and the header and is arranged to disperse a flow from an inlet flow path a heat exchanger matrix. The swirler extends a only portion of the length of the header between the conduit and the heat exchanger matrix and thereby provides space within the header for fluid to diffuse before entering the heat exchanger matrix.

Abstract: A method of forming a component for a heat exchanger is disclosed. The method comprises machining a portion of a metal sheet to form a plurality of protrusions, and forming apertures in the portion of the metal sheet so as to form a plurality of ribs defined by adjacent ones of the apertures, wherein at least one protrusion is located on each of said ribs.

Abstract: A method of manufacturing a heat exchanger comprising a body and a support embedded within the body. The support comprises a different material and/or a different material structure to the body and hence has at least one material property which is different to that of the body. The method comprises; forming at least a first portion of the support with a first material and a first material structure using a first additive manufacturing step; and forming at least a first portion of the body with a second material and a second material structure using a second additive manufacturing step. The first material is different to the second material and/or the first material structure is different to the second material structure.

Abstract: A method of forming a component for a heat exchanger is disclosed. The method comprises machining a portion of a metal sheet to form a plurality of protrusions, and forming apertures in the portion of the metal sheet so as to form a plurality of ribs defined by adjacent ones of the apertures, wherein at least one protrusion is located on each of said ribs.

Abstract: A method of manufacturing a heat exchanger comprising a body and a support embedded within the body. The support comprises a different material and/or a different material structure to the body and hence has at least one material property which is different to that of the body. The method comprises; forming at least a first portion of the support with a first material and a first material structure using a first additive manufacturing step; and forming at least a first portion of the body with a second material and a second material structure using a second additive manufacturing step. The first material is different to the second material and/or the first material structure is different to the second material structure.

Abstract: There is provided a heat exchanger comprising: a conduit defining an inlet flow path for a fluid; a header disposed to receive a flow from the inlet flow path; a heat exchanger matrix disposed to receive a flow from the header; and a swirler disposed within the conduit and the header. The swirler is arranged to disperse a flow from the inlet flow path over the heat exchanger matrix. The conduit, header, and swirler are formed as a unitary piece by additive manufacturing.

Abstract: A heat exchanger comprises a conduit with an interior surface which defines a first flow passage. A first plurality of fins project inwardly from the interior surface of the conduit. The first plurality of fins are angled relative to a longitudinal axis (X) of the conduit so as to form helical flowpaths for fluid flowing through the first flow passage. A second flow passage disposed outwardly of the interior surface and radially outwardly of the first plurality of fins.