Abstract: A cast part includes an outermost wall, at least one inner wall defining at least two internal passages and at least one cast cooling fin extending from an outer surface. The cast part including a cross-sectional circular area spanning at least a portion of each of four internal passages includes a ratio of interior empty space to inner wall space that improves heat transfer.

Abstract: A cast part includes an outermost wall, at least one inner wall defining at least two internal passages and at least one cast cooling fin extending from an outer surface. The cooling fin includes a ratio of fin height to an average fin thickness that is greater than 2.0 and no more than 18.0. A method 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 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 welded assembly includes a first sheet and a second sheet. The second sheet is disposed over a portion of the first sheet and defines an overlap portion between the first and second sheets. A weld fastening the second sheet to the first sheet in the overlap area connects the second sheet to the first sheet for distributing stress uniformly across a welded portion of the overlap area.

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: 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 is disclosed and includes a plate portion including a plurality of internal passages extending between an inlet and an outlet and at least one means for providing fluid communication between at least two of the plurality of internal passages.

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 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 gas turbine engine includes a bypass duct for a bypass airflow and a diffuser case including an inlet in communication with the bypass duct for communicating a bypass flow to a heat exchanger portion. An outlet passage extends through the bypass duct to exhaust airflow exiting the heat exchanger portion outside of the bypass duct.

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 is disclosed and includes a plate portion including a plurality of internal passages extending between an inlet and an outlet and at least one means for providing fluid communication between at least two of the plurality of internal passages.

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 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 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 cast part includes an outermost wall, at least one inner wall defining at least two internal passages and at least one cast cooling fin extending from an outer surface. The cooling fin includes a ratio of fin height to an average fin thickness that is greater than 2.0 and no more than 18.0. A method is also disclosed.

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.