Abstract: A cast plate heat exchanger includes an inner surface of a passage with a first group of augmentation features with a first density across the inner surface. An outer surface includes a second inlet end and a second group of augmentation features arranged with a second density across the outer surface. The first density and second density of augmentation features are located in a targeted manner to reduce thermal stresses.

Abstract: A heat exchanger assembly includes a plate including a plate portion having a leading edge, a trailing edge, an inlet side and an outlet side. The leading edge of the plate portion includes a terminal tip and a varying radius that decreases in a direction toward the terminal tip. An inlet manifold is on the inlet side. An outlet manifold is on the outlet side. A cast plate for a plate fin heat exchanger is also disclosed.

Abstract: A heat exchanger includes a primary plate including a first surface, a second surface, a leading edge, a trailing edge and a plurality of internal passages extending between an inlet and an outlet. A secondary plate is attached to at least one of the first surface and second surface of the primary plate. The secondary plate includes heat transfer structures. A method is also disclosed.

Abstract: A featured embodiment of a cast plate heat exchanger assembly includes a cast plate including a plate portion defining a plurality of internal passages. A plurality of fin portions extend from the plate portion. First augmentation structures are disposed on surfaces of the fin portions for conditioning cooling airflow to enhance transfer of thermal energy. A method is also disclosed.

Abstract: A cast plate heat exchanger includes a first surface including a first surface inlet end and a first group of augmentation features defining a first average density of augmentation features across the first surface. A second surface is in heat transfer communication with the first surface. The second surface includes a second surfaces inlet end and a second group of augmentation features defining a second average density of augmentation features across the second surface. A total augmentation feature density ratio is defined from the first average density of augmentation features to the second average density of augmentation features. A first region is shared by both the first surface and the second surface and covers at least a portion of the first surface inlet end. The first region includes a first region augmentation feature density ratio that is less than the total augmentation feature density ratio.

Abstract: A heat exchanger assembly includes a plate including a plate portion having a leading edge, a trailing edge, an inlet side and an outlet side. The leading edge of the plate portion includes a terminal tip and a varying radius that decreases in a direction toward the terminal tip. An inlet manifold is on the inlet side. An outlet manifold is on the outlet side. A cast plate for a plate fin heat exchanger is also disclosed.

Abstract: A plate fin heat exchanger includes a first cast plate assembly includes at least two plate portions separated by at least one cooling channel. Each of the two plate portions include a plurality of internal passages extending between a corresponding plurality of inlets and outlets. A common inlet perimeter surrounds the plurality of inlets from each of the two plate portions and an outlet perimeter surrounds the plurality of outlets from each of the two plate portions. An inlet manifold is attached at an inlet joint to the inlet perimeter. An outlet manifold is attached at an outlet joint to the outlet perimeter. A method is also disclosed.

Abstract: A heat exchanger includes a plate portion including a top surface, bottom surface, a leading edge, a trailing edge and a plurality of internal passages extending between an inlet and an outlet. A fin portion extends outward from one of the top surface and the bottom surface. The fin portion and the leading edge of the plate portion define a leading edge contour. A cast plate for a heat exchanger and a method are also disclosed.

Abstract: A heat exchanger includes a plate portion including a top surface, bottom surface, a leading edge, a trailing edge and a plurality of internal passages extending between an inlet and an outlet. A plurality of fin portion rows are included. A first row of the plurality of fin portions includes at least two discrete fin portions and a second row of the plurality of in portions includes fewer fin portions than the first row. The first row is closer to the inlet than the second row. A cast plate for a heat exchanger and a method are also disclosed.