Abstract: A fluid cooler assembly comprises a vertically stacked first type and second different type of tubular panel subassembly construction integrated with a third subassembly of external corrugated fin construction positioned above and below each tubular panel subassembly. The first type tubular panel subassembly has an internal central flow region configured with a bilateral linear flow channeled subregion adapted for controlling the hydraulic behavior of the internal tubular coolant fluid flow. The second tubular panel subassembly has an internal tubular central flow channel region configured with a bilateral cross-flow channel region adapted for optimizing heat transfer.

Abstract: An aluminum alloy fluid heat exchanger comprises first and second elongate, generally flat, aluminum alloy fluid heat exchanger tubes, each having an upper and a lower surface and having a fluid port inlet and a fluid port outlet. The first tube has a series of small protrusions formed at its lower surface and the second tube has a matching series of protrusions formed at its upper surface, the first tube being stacked on top of the second tube with the protrusions on the first tube in contact with the protrusions on the second tube. A thin sheet of a dissimilar metal, preferably cold rolled steel having a thickness of about 0.3 millimeters is installed between the protrusions on the first and second tubes. The protrusions provide a spacing of at least about 0.42 millimeters between major portions of the first and second heat exchanger tubes. A corresponding method of constructing an aluminum alloy heat exchanger is described.