Method for manufacturing a hybrid heat exchanger

Abstract

A method for manufacturing a heat exchanger structure includes additively forming a top layer of a header after disposing a corrugated core within the header to retain the corrugated core within the header. Additively forming the top layer can include filling the corrugated core with powder until a suitable layer of powder overlays the corrugated core and the header and sintering the powder to form the top layer of the header.

1 - 12 . (canceled) 
     
     
         13 . A heat exchanger structure, comprising:
 an additively manufactured header defining a plurality of fluid channels therein and an opening; and   a corrugated core disposed within the additively manufactured header, the corrugated core defining flow channels therethrough and having a wall thickness of about less than or equal to 0.004 inches, wherein the flow channels are disposed in fluid communication with the plurality of fluid channels.   
     
     
         14 . The heat exchanger structure of  claim 13 , wherein the corrugated core is non-additively manufactured.