Abstract: A method of forming a cast heat exchanger plate includes forming at least one hot core plate defining internal features of a one piece heat exchanger plate and at least one first set of interlocking features. At least one cold core plate is formed defining external features of the heat exchanger plate and at least one second set of interlocking features. A core assembly is assembled where each hot core plate is directly interlocked to at least one cold core plate. A wax pattern is formed with the core assembly with an external shell formed over the wax pattern. The wax pattern is removed to form a space between the core assembly and the external shell. The space is filled with a molten material. Once the molten material has solidified, the external shell and the core are removed.

Abstract: A method of forming a cast heat exchanger plate includes forming at least one hot core plate defining internal features of a one piece heat exchanger plate and at least one first set of interlocking features. At least one cold core plate is formed defining external features of the heat exchanger plate and at least one second set of interlocking features. A core assembly is assembled wherein each hot core plate is directly interlocked to the at least one cold core plate. A wax pattern is formed with the core assembly. An external shell is formed over the wax pattern. The wax pattern is removed to form a space between the core assembly and the external shell. The space is filled with a molten material and cures the molten material. The external shell is removed. The core assembly is removed. A core assembly for a cast heat exchanger is also disclosed.

Abstract: A method of forming a cast heat exchanger plate includes forming at least one hot core plate defining internal features of a one piece heat exchanger plate and at least one first set of interlocking features. At least one cold core plate is formed defining external features of the heat exchanger plate and at least one second set of interlocking features. A core assembly is assembled wherein each hot core plate is directly interlocked to the at least one cold core plate. A wax pattern is formed with the core assembly. An external shell is formed over the wax pattern. The wax pattern is removed to form a space between the core assembly and the external shell. The space is filled with a molten material and cures the molten material. The external shell is removed. The core assembly is removed. A core assembly for a cast heat exchanger is also disclosed.

Abstract: In a featured embodiment, a heat exchanger includes a plate including a plate portion having outer walls. A plurality of internal passages extend between end portions. A ratio between an outer wall cross-sectional thickness at one of the end portions and a cross-sectional wall thickness of the outer wall within the plate portion is greater than 2.5 and no more than 10. An inlet manifold is attached to the inlet end. An outlet manifold is attached to the outlet end.

Abstract: A heat exchanger has: an inlet manifold having an inlet port; and an outlet manifold having an outlet port. A first gas flowpath passes from the inlet port to the outlet port. A plurality of plate banks are positioned end-to-end, each plate bank having a plurality of conduits with interiors along respective branches of the first gas flowpath, a second gas flowpath extending across exteriors of the plurality of conduits. One or more docks couple adjacent ends of the plurality of plate banks.

Abstract: A method of forming a cast heat exchanger plate includes forming at least one hot core plate defining internal features of a one piece heat exchanger plate and at least one first set of interlocking features. At least one cold core plate is formed defining external features of the heat exchanger plate and at least one second set of interlocking features. A core assembly is assembled wherein each hot core plate is directly interlocked to the at least one cold core plate. A wax pattern is formed with the core assembly. An external shell is formed over the wax pattern. The wax pattern is removed to form a space between the core assembly and the external shell. The space is filled with a molten material and cures the molten material. The external shell is removed. The core assembly is removed. A core assembly for a cast heat exchanger is also disclosed.

Abstract: In a featured embodiment, a heat exchanger includes a plate including a plate portion having outer walls. A plurality of internal passages extend between end portions. A ratio between an outer wall cross-sectional thickness at one of the end portions and a cross-sectional wall thickness of the outer wall within the plate portion is greater than 2.5 and no more than 10. An inlet manifold is attached to the inlet end. An outlet manifold is attached to the outlet end.

Abstract: An airfoil for use in a gas turbine engine is provided. The airfoil having: a pressure surface and a suction surface each extending axially from a leading edge to a trailing edge of the airfoil, at least one of the pressure surface, the suction surface, the leading edge and the trailing edge terminating at an edge of a tip section of the airfoil; a plurality of internal cooling channels located within the airfoil; and at least one cooling hole in fluid communication with at least one of the plurality of internal cooling channels, wherein the at least one cooling hole is aligned with an opening or diffuser that extends directly from the at least one cooling hole and wherein the opening or diffuser is formed in and extends through the edge of the tip section of the airfoil.

Abstract: A gas turbine engine airfoil includes a body that provides an exterior airfoil surface that extends in a radial direction to a tip. The exterior surface has a leading edge in a forward direction and a trailing edge in an aft direction. The tip includes a squealer pocket that has a recess surface. A cooling passage is arranged in the body. Each of the cooling holes extends from an inlet at the cooling passage to an outlet at the recessed surface. The inlet and outlet are arranged at an angle in an angular direction relative to the recessed surface. The angular direction is toward at least one of the forward and aft directions.

Abstract: An airfoil for use in a gas turbine engine is provided. The airfoil having: a pressure surface and a suction surface each extending axially from a leading edge to a trailing edge of the airfoil, at least one of the pressure surface, the suction surface, the leading edge and the trailing edge terminating at an edge of a tip section of the airfoil; a plurality of internal cooling channels located within the airfoil; and at least one cooling hole in fluid communication with at least one of the plurality of internal cooling channels, wherein the at least one cooling hole is aligned with an opening or diffuser that extends directly from the at least one cooling hole and wherein the opening or diffuser is formed in and extends through the edge of the tip section of the airfoil.

Abstract: A gas turbine engine airfoil includes a body that provides an exterior airfoil surface that extends in a radial direction to a tip. The exterior surface has a leading edge in a forward direction and a trailing edge in an aft direction. The tip includes a squealer pocket that has a recess surface. A cooling passage is arranged in the body. Each of the cooling holes extends from an inlet at the cooling passage to an outlet at the recessed surface. The inlet and outlet are arranged at an angle in an angular direction relative to the recessed surface. The angular direction is toward at least one of the forward and aft directions.