Hybrid manufacturing process for heat exchanger

Abstract

A heat exchanger includes a base and a plurality of substantially parallel and substantially vertical walls spaced apart and integrally formed with the base via additive manufacturing. The heat exchanger also includes at least one parting sheet not integrally formed with the plurality of walls, but being attached to the plurality of walls, defining flow channels between the walls, the base, and the at least one parting sheet.

1 . A heat exchanger comprising:
 a base;   a plurality of walls being substantially parallel and substantially vertical while being manufactured and spaced apart and integrally formed with the base via additive manufacturing; and   at least one parting sheet not integrally formed with the plurality of walls, but being attached to the plurality of walls, defining flow channels between the walls, the base, and the at least one parting sheet.   
     
     
         2 . The heat exchanger of  claim 1 , further comprising an upper most layer having an upper most cap attached to the plurality of walls within the upper most layer. 
     
     
         3 . The heat exchanger of  claim 1 , further comprising a flow enhancement feature or a heat transfer enhancement feature attached to the base or at least one parting sheet. 
     
     
         4 . The heat exchanger of  claim 3 , wherein the flow enhancement feature or the heat transfer enhancement feature is a point, fin, bar, ramp, or airfoil. 
     
     
         5 . The heat exchanger of  claim 1 , wherein the plurality of walls, at least one parting sheet, and the base define two sets of fluid channels, which are for porting a hot fluid through the first set of fluid channels and for porting a cold fluid through the second set of fluid channels. 
     
     
         6 . The heat exchanger of  claim 5 , wherein the first set of fluid channels and the second set of channels form layers and the first set of fluid channel layers alternate with the second set of channel layers. 
     
     
         7 . The heat exchanger of  claim 6 , wherein the alternating first and second fluid layers are arranged in a parallel flow, counter-flow, or cross-flow arrangement. 
     
     
         8 . The heat exchanger of  claim 1 , wherein the base is formed of a cast or wrought material. 
     
     
         9 . The heat exchanger of  claim 1 , wherein the base is formed using additive manufacturing techniques. 
     
     
         10 . A method of constructing a heat exchanger, the method comprising:
 (a) providing a base;   (b) additively manufacturing a plurality of substantially parallel and substantially vertical walls, wherein the plurality of walls are spaced apart and attached to the base;   (c) removing at least a portion of a build powder located between the plurality of walls before attaching a parting sheet;   (d) attaching the parting sheet to the plurality of walls;   (e) additively manufacturing a plurality of substantially parallel and substantially vertical walls, wherein the plurality of walls are spaced apart and attached to the parting sheet;   (f) repeating steps (c)-(e) until an upper most layer has been formed; and   (g) attaching an upper most cap to the substantially parallel and substantially vertical walls of the upper most layer.