Abstract: A method of manufacturing a heat exchanger. The method includes additively manufacturing a first body with a first plurality of passages extending through the first body. Additively manufacturing a second body with a second plurality of passages extending through the second body. The method also includes, interlocking the first body with the second body such that the first plurality of passages is aligned with the second plurality of passages and fluidically connected with the second plurality of passages.

Abstract: A heat exchanger includes a first flow circuit structure having at least a first portion defined by a plurality of conduits and a second flow circuit structure having at least a second portion disposed at the first portion such that walls of the second portion are disposed between the conduits and are free to move relative to the conduits. Fluid flowing through the first flow circuit structure is fluidically isolated from fluid flowing through the second flow circuit structure.

Abstract: A heat exchanger includes a first side opposite a second side and a third side opposite a fourth side and a cold layer with an inlet at the first side of the heat exchanger, an outlet at the second side of the heat exchanger, and a cold passage extending from the inlet to the outlet. The heat exchanger also includes a hot layer with an inlet manifold at the third side of the heat exchanger extending between the first side and the second side, an outlet manifold at the fourth side of the heat exchanger opposite the inlet manifold and extending between the first side and the second side, a hot passage extending from the inlet manifold to the outlet manifold, and a tube on the first side of the heat exchanger extending from the third side to the fourth side.

Abstract: A heat exchanger assembly includes a first member defining fluid passages therein for a first heat exchanger fluid. A second member defines fluid passages therein for a second heat exchanger fluid. The second member is engaged to the second member with an interference fit. A method of assembling a heat exchanger includes thermally resizing at least one of a first heat exchanger member and a second heat exchanger member and assembling the second heat exchanger member to the first heat exchanger member. The method includes thermally equalizing the first and second heat exchanger members to engage the second heat exchanger member to the first heat exchanger member with an interference fit.

Abstract: A method of manufacturing a heat exchanger. The method includes additively manufacturing a first body with a first plurality of passages extending through the first body. Additively manufacturing a second body with a second plurality of passages extending through the second body. The method also includes, interlocking the first body with the second body such that the first plurality of passages is aligned with the second plurality of passages and fluidically connected with the second plurality of passages.

Abstract: A heat exchanger includes a first fluid manifold extending along a first fluid axis from a first fluid inlet to a first fluid outlet. The first fluid manifold comprises a inlet header, a outlet header, and a multi-helical core section. The inlet header is disposed to fork the first fluid inlet into a plurality of first fluid branches distributed laterally across a plane normal to the first fluid axis. The outlet header is disposed to combine the plurality of first fluid branches into the first fluid outlet. The multi-helical core section fluidly connects the inlet header to the outlet header via a plurality of laterally distributed helical tubes, each helical tube corresponding to one of the plurality of first fluid branches and oriented parallel to all others of the plurality of helical tubes at each axial location along the first fluid axis.

Abstract: A heat exchanger includes a first side opposite a second side and a third side opposite a fourth side and a cold layer with an inlet at the first side of the heat exchanger, an outlet at the second side of the heat exchanger, and a cold passage extending from the inlet to the outlet. The heat exchanger also includes a hot layer with an inlet manifold at the third side of the heat exchanger extending between the first side and the second side, an outlet manifold at the fourth side of the heat exchanger opposite the inlet manifold and extending between the first side and the second side, a hot passage extending from the inlet manifold to the outlet manifold, and a tube on the first side of the heat exchanger extending from the third side to the fourth side.

Abstract: A heat exchanger includes a first fluid manifold extending along a first fluid axis from a first fluid inlet to a first fluid outlet. The first fluid manifold includes a first fluid inlet header, a first fluid outlet header, and a nested helical core section. The first fluid inlet header is disposed to fork the first fluid inlet into a plurality of first fluid branches distributed circumferentially and radially about the first fluid axis. The first fluid outlet header is disposed to combine the plurality of first fluid branches into the first fluid outlet. The nested helical core section fluidly connects the first fluid inlet header to the first fluid outlet header via a plurality of nested helical tubes, and includes radially inner and outer groups of circumferentially distributed helical tubes.

Abstract: A heat exchanger header for receiving a first fluid includes a tubular primary fluid channel oriented along a first axis and having a first cross-sectional area. A first branched region adjacent to the primary fluid channel fluidly connects to a plurality of tubular secondary fluid channels, each having a second cross-sectional area, and a second branched region adjacent to each of the secondary fluid channels fluidly connects to a plurality of tubular tertiary fluid channels, each having a third cross-sectional area. The second cross-sectional area is greater than the third cross-sectional area.

Abstract: A core arrangement for a heat exchanger includes a plurality of inlets arranged around an axis, a plurality of outlets arranged around the axis, and a plurality of bowed conduits arranged around the axis. The bowed conduits are structurally independent, connect the plurality of inlets to the plurality of outlets, bow outward from the axis between the plurality of inlets and the plurality of outlets, and provide thermal compliance to the core.

Abstract: A core arrangement for a heat exchanger includes a first core layer disposed along a first plane and having an inlet and outlet oriented along a first axis within the first plane and a first core stage disposed in fluid communication between the inlet and the outlet. The first core stage includes a first upstream fluid intersection downstream of and adjacent the inlet and having a first inlet continuation and a first bifurcation. The first core stage further includes a first downstream fluid intersection upstream of and adjacent the outlet and having a first outlet continuation and a first recombination. A plurality of first core tubes fluidly connect the first bifurcation to the first recombination. The first core layer further includes a second core stage disposed in fluid communication between the first inlet continuation and the first outlet continuation.

Abstract: A heat exchanger includes a plurality of first and second fluid passages. The first fluid passages are defined by a pair of opposing first fluid passage walls and a plurality of first fluid diverters disposed between the first fluid passages walls. The second fluid passages are defined by a pair of opposing second fluid passage walls and a plurality of second fluid diverters disposed between the second fluid passage walls. The second fluid diverters include a body portion and a leading edge portion. The first fluid passage walls form a first fluid leading edge that extends upstream of the leading edge portion of the second fluid diverters. The second fluid passages extend in a direction perpendicular to the direction of the first fluid passages.

Abstract: A method of forming an integral drain for a heat exchanger is provided. The method includes forming a plurality of passage walls to define a plurality of passages with an additive manufacturing process, each of the passage walls having a non-linear portion. The method also includes integrally forming a drain wall with at least one of the passage walls with the additive manufacturing process to define a drain for each of the plurality of passages, the drain wall located proximate the non-linear portion of each of the plurality of passage walls.

Abstract: A core arrangement for a heat exchanger includes a first core layer. The first core layer includes first upstream and downstream ends, first and second parting sheets parallel to one another, and a plurality of adjacent fins disposed between the first and second parting sheets. Each of the plurality of fins extends from a surface of the first parting sheet to a surface of the second parting sheet, and longitudinally between the first upstream end and the first downstream end. The plurality of fins are further laterally arranged to define a plurality of first fluid passages. Each of a subset of the plurality of fins includes an internal slot positioned away from the first upstream end and the first downstream end.

Abstract: A heat exchanger system is disclosed herein that extends between a first component and a second component. The heat exchanger system includes a hot flow path configured to convey hot fluid between the first component and the second component, a cool flow path configured to convey cool fluid, and a heat exchanger located between the first component and the second component along the hot flow path and the cool flow path. The heat exchanger includes at least one curve to accommodate the hot flow path and is configured to reduce the temperature of the hot fluid by allowing the transfer of thermal energy from the hot fluid to the cool fluid.

Abstract: A heat exchanger includes a core having a nonrectangular cross-sectional area, a plurality of cold flow layers centered about a centerline with each of the plurality of cold flow layers separated by corresponding walls. The heat exchanger also includes a plurality of hot flow tubes corresponding to each of the plurality of cold flow layers.

Abstract: A heat exchanger includes a first flow circuit structure having at least a first portion defined by a plurality of conduits and a second flow circuit structure having at least a second portion disposed at the first portion such that walls of the second portion are disposed between the conduits and are free to move relative to the conduits. Fluid flowing through the first flow circuit structure is fluidically isolated from fluid flowing through the second flow circuit structure.

Abstract: A heat exchanger includes a first fluid manifold extending along a first fluid axis from a first fluid inlet to a first fluid outlet. The first fluid manifold includes first fluid inlet and outlet headers, and a helical core section. The inlet header is disposed to branch the first fluid inlet into a plurality of first fluid branches, and the outlet header is disposed to combine the plurality of first fluid branches into the first fluid outlet. The core section fluidly connects the inlet header to the outlet header via a plurality of helical tubes, such that each helical tube corresponds to one of the plurality of first fluid branches.

Abstract: A heat exchanger includes a first fluid manifold extending along a first fluid axis from a first fluid inlet to a first fluid outlet. The first fluid manifold includes a first fluid inlet header, a first fluid outlet header, and a nested helical core section. The first fluid inlet header is disposed to fork the first fluid inlet into a plurality of first fluid branches distributed circumferentially and radially about the first fluid axis. The first fluid outlet header is disposed to combine the plurality of first fluid branches into the first fluid outlet. The nested helical core section fluidly connects the first fluid inlet header to the first fluid outlet header via a plurality of nested helical tubes, and includes radially inner and outer groups of circumferentially distributed helical tubes.

Abstract: A heat exchanger includes a first fluid manifold extending along a first fluid axis from a first fluid inlet to a first fluid outlet. The first fluid manifold comprises a inlet header, a outlet header, and a multi-helical core section. The inlet header is disposed to fork the first fluid inlet into a plurality of first fluid branches distributed laterally across a plane normal to the first fluid axis. The outlet header is disposed to combine the plurality of first fluid branches into the first fluid outlet. The multi-helical core section fluidly connects the inlet header to the outlet header via a plurality of laterally distributed helical tubes, each helical tube corresponding to one of the plurality of first fluid branches and oriented parallel to all others of the plurality of helical tubes at each axial location along the first fluid axis.