US-20260126249-A1 - HEAT AUGMENTATION FEATURES IN A CAST HEAT EXCHANGER

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.

Inventors

• Michael A. Disori
• William P. Stillman
• Alexander Broulidakis
• Dave J. Hyland
• Jeremy Styborski
• Adam J. Diener
• Matthew A. Devore
• Dominic J. Mongillo, Jr.

Assignees

• RTX CORPORATION

Dates

Publication Date

20260507

Application Date

20251219

Claims (18)

1. 1 . A method of assembling a heat exchanger comprising: forming a cast plate portion defining a plurality of internal passages; forming a plurality of fin portions extending from the plate portion; and forming first augmentation structures disposed on surfaces of the plurality of fin portions for conditioning cooling airflow to enhance transfer of thermal energy.
2. 2 . The method as recited in claim 1 , wherein the cast plate portion, the plurality of fin portions and the first augmentation structures are formed as single unitary cast structure.
3. 3 . The method as recited in claim 1 , further comprising forming a channel bottom bounded by at least two of the plurality of fin portions and forming the first augmentation structures to be disposed on the channel bottom.
4. 4 . The method as recited in claim 3 , further comprising forming the first augmentation structures on both the channel bottom and sides of the plurality of fin portions.
5. 5 . The method as recited in claim 1 , further comprising forming second augmentation structures on walls of the plurality of internal passages.
6. 6 . The method as recited in claim 5 , further comprising forming at least one of the first augmentation structures and the second augmentation structures as trip strips, wherein the trip strips are formed in an orientation as one of a chevron pattern and a w-shaped pattern.
7. 7 . The method as recited in claim 5 , wherein at least one of the first augmentation structures and the second augmentation structures comprise at least one of a plurality of depressions and a plurality of pedestals.
8. 8 . The method as recited in claim 1 , further comprising forming augmentation structures on at least one of an inlet manifold and an outlet manifold and attaching the inlet manifold and outlet manifold to opposite ends of the cast plate portion in fluid communication with the plurality of internal passages.
9. 9 . A cast plate heat exchanger assembly comprising: a cast plate portion defining a plurality of internal passages extending between an inlet face and an outlet face; a plurality of cast fin portions extending from the cast plate portion; a plurality of first augmentation structures disposed on surfaces of the plurality of the cast fin portions for conditioning cooling airflow to enhance transfer of thermal energy; an inlet manifold configured for communicating a flow to the inlet face; and an outlet manifold configured for receiving and directing an outlet flow from the outlet face.
10. 10 . The heat exchanger as recited in claim 9 , wherein an outer surface of the cast plate portion defines a channel bottom bounded by at least two of the plurality of fin portions and the first augmentation structures are further disposed on the channel bottom.
11. 11 . The heat exchanger as recited in claim 10 , wherein the first augmentation structures are disposed on both the channel bottom and sides of the plurality of fin portions.
12. 12 . The heat exchanger as recited in claim 9 , wherein the plurality of internal passages comprises a plurality of second augmentation structures that are an integral part of the cast plate portion.
13. 13 . The heat exchanger as recited in claim 12 , wherein at least one of the plurality of first augmentation structures and the plurality of second augmentation structures include a density that varies over a length in a direction of flow.
14. 14 . The heat exchanger as recited in claim 12 , wherein each of the plurality of internal passages is closed between the inlet face and the outlet face.
15. 15 . The heat exchanger as recited in claim 12 , wherein at least one of the first augmentation structures and the plurality of the second augmentation structures comprise trip strips.
16. 16 . The heat exchanger as recited in claim 15 , wherein the trip strips are orientated in one of an angled pattern, a chevron pattern, and a w-shaped pattern.
17. 17 . The heat exchanger as recited in claim 12 , wherein at least one of the plurality of the first augmentation structures and the plurality of the second augmentation structures comprise at least one of a plurality of depressions and a plurality of pedestals.
18. 18 . The heat exchanger as recited in claim 9 , wherein at least one of the inlet manifold and the outlet manifold include augmentation structures.

Description

CROSS REFERENCE TO RELATED APPLICATION This application is a Divisional of U.S. patent application Ser. No. 16/280,179 filed Feb. 20, 2019, which claims priority to U.S. Provisional Application No. 62/653,128 filed on Apr. 5, 2018. BACKGROUND A plate fin heat exchanger includes adjacent flow paths that transfer heat from a hot flow to a cooling flow. The flow paths are defined by a combination of plates and fins that are arranged to transfer heat from one flow to another flow. The plates and fins are created from sheet metal material brazed together to define the different flow paths. Thermal gradients present in the sheet material create stresses that can be very high in certain locations. Increasing temperatures and pressures can result in stresses on the structure that can exceed material and assembly capabilities. Turbine engine manufactures utilize heat exchangers throughout the engine to cool and condition airflow for cooling and other operational needs. Improvements to turbine engines have enabled increases in operational temperatures and pressures. The increases in temperatures and pressures improve engine efficiency but also increase demands on all engine components including heat exchangers. Turbine engine manufacturers continue to seek further improvements to engine performance including improvements to thermal, transfer and propulsive efficiencies. SUMMARY 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. In another embodiment according to the previous embodiment, a channel bottom is bounded by at least two of the plurality of fin portions and the first augmentation structures are further disposed on the channel bottom. In another embodiment according to any of the previous embodiments, the first augmentation structures are disposed on both the channel bottom and sides of the fin portions. In another embodiment according to any of the previous embodiments, the plurality of internal passages includes second augmentation structures that are an integral part of the plate portion. In another embodiment according to any of the previous embodiments, at least one of the first augmentation structures and the second augmentation structures include trip strips. In another embodiment according to any of the previous embodiments, the trip strips are orientated in one of an angled pattern, a chevron pattern, and a w-shaped pattern. In another embodiment according to any of the previous embodiments, at least one of the first augmentation structures and the second augmentation structures include one of dimples, depressions, and pedestals. In another embodiment according to any of the previous embodiments, an inlet manifold and an outlet manifold are disposed on opposite ends of the cast plate and are in fluid communication with the plurality of internal passages. At least one of the inlet manifold and the outlet manifold include augmentation structures. In another embodiment according to any of the previous embodiments, the plate portion, the fin portions and the first augmentation features are portions of a single unitary part. In another featured embodiment, 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 means for thermal energy transfer are disposed on surfaces of the fin portions for conditioning cooling airflow to enhance transfer of thermal energy. In another embodiment according to the previous embodiment, a channel bottom is bounded by at least two of the plurality of fin portions and the first means for thermal energy transfer are further disposed on the channel bottom. In another embodiment according to any of the previous embodiments, the plurality of internal passages include a second means for thermal energy transfer that are an integral part of the plate portion. In another embodiment according to any of the previous embodiments, an inlet manifold and an outlet manifold are disposed on opposite ends of the cast plate and in fluid communication with the plurality of internal passages. At least one of the inlet manifold and the outlet manifold include a means for thermal energy transfer. In another embodiment according to any of the previous embodiments, the plate portion, fin portions and the first means for thermal energy transfer are portions of a single unitary part. In another featured embodiment, a method of assembling a heat exchanger includes forming a plate portion defining a plurality of internal passages. A plurality of fin portions are formed extending from the plate portion. First augmentation structures disposed on surfaces of the fin por