Abstract: An apparatus and a method are provided for a modular intercooler block that may be fabricated by way of direct metal printing and assembled to form larger intercoolers. The modular intercooler block comprises cooling fins that are spaced between first and second core headers to allow passage of an airstream. Countersunk holes are arranged on the first and second core headers and configured to receive grommets when the first or second core header is fastened to another core header comprising similarly arranged countersunk holes. A core tube extends along an undulating path from each countersunk hole in the first core header, through the multiplicity of cooling fins, to a similar countersunk hole in the second core header. The core tubes may include thin copper walls and spiraled inner passages to enhance heat transfer to the airstream passing through the multiplicity of cooling fins.

Abstract: A heat exchanger having an optimum design considering a thermal capacity of an end portion of an extrusion tube to significantly improve heat transfer performance by optimizing a shape and a thickness of the end portion of the tube, and a heat exchanger having an optimum design obtained based on a structured rule to enable easy application to other tubes with various dimensions. The heat exchanger has an end portion of a tube has a cross section in a quadrangular shape with rounded corners, each having a radius in a range of 15% to 45% of a height of the tube.

Abstract: A tubular connection and methods of manufacturing a box member. The tubular connection includes a box member that includes an internal thread and a pin member that includes an external thread. The external thread is adapted to threadedly engage the internal thread. A substantially helical groove is formed on an outer surface of the box member. The method of manufacturing the box member includes selecting an outer diameter for a box member that causes the tool joint to have a greater than a selected bending strength ratio. A helical groove is formed on the outer diameter of the box member such that the helical groove reduces the bending strength ratio to be about the selected bending strength ratio. An internal thread is formed on an internal surface of the box member. Another method of manufacturing the box member includes forming an internal thread on an internal surface of a cylinder and forming a substantially helical groove on an outer surface of the cylinder.

Abstract: A method of manufacturing a thick walled Moineau-style stator entails drawing a thick walled tube through rotatable internal and external dies to form a helical outer profile including crests and through on the tube. The tube initially has one end with a diameter smaller than the others, with the smaller diameter end being inserted between the inner and outer dies, where it is seized and drawn through the dies.