Additive heat exchanger and method of forming

Abstract

An electroformed heat exchanger suitable for use between rotating blades and seals in a stationary housing of a turbine engine. The heat exchanger includes: a non-electroformed support plate having a radially outer surface and a radially inner surface; an electroformed conduit disposed along the radially outer surface; an electroformed track disposed on the radially inner surface; and an electroformed reinforcement formed from a portion of the electroformed conduit and the electroformed track.

Description

Technical Field

[0001] This disclosure generally relates to an additively manufactured heat exchanger, and more specifically to an electroformed heat exchanger. Background Technology

[0002] Turbine engines, particularly gas turbine engines, are rotary engines that extract energy from a continuous flow of working air passing through a compressor section (where working air is compressed), a combustion chamber section (where fuel is added to the working air and ignited), and a turbine section (where the combusted working air expands and extracts work from the working air to drive the compressor section and other systems, and to provide thrust in an aircraft configuration). The compressor and turbine stages comprise axially arranged pairs of rotating blades and fixed vanes. A gas turbine engine may be arranged as an engine core comprising at least an axially flowing compressor section, a combustion chamber section, and a turbine section, and defining at least one rotating element or rotor and at least one stationary component or stator.

[0003] During operation, the engine core of a gas turbine engine generates a significant amount of heat. Heat exchangers or thermal barriers provide a way to transfer or shield the heat generated from the engine core, allowing other parts of the gas turbine engine to be decoupled from the heat of the engine core. For example, heat exchangers can be arranged in a ring around a portion of the turbine engine to shield components radially outward from the heat of the engine core. Summary of the Invention

[0004] In one aspect, this disclosure relates to an electroformed heat exchanger suitable for use in a turbine engine having an engine centerline, the electroformed heat exchanger comprising: an electroformed support plate having a radially outer surface and a radially inner surface, a reinforcing opening extending between the radially inner surface and the radially outer surface, and a plurality of cooling openings extending between the radially inner surface and the radially outer surface; an electroformed conduit having an internal fluid conduit fluidly connected to the plurality of cooling openings; an electroformed rail having at least one internal channel fluidly connected to the plurality of cooling openings, wherein the internal channel is fluidly connected to the internal fluid conduit through the plurality of cooling openings; and an electroformed reinforcing member formed by a portion of the electroformed conduit and the electroformed rail and covering the reinforcing opening.

[0005] In another aspect, this disclosure relates to a method of electroforming a heat exchanger suitable for use in a turbine engine having an engine centerline, the method comprising: electroforming a conduit on a first sacrificial element supported by a non-sacrificial support plate having a radially outer surface and a radially inner surface, a reinforcing opening extending between the radially inner surface and the radially outer surface, and a plurality of cooling openings extending between the radially inner surface and the radially outer surface, the first sacrificial element having a reinforcing portion covering the reinforcing opening on the radially outer surface and a conduit portion adjacent to the plurality of cooling openings on the radially outer surface; electroforming a track on a second sacrificial element, the second sacrificial element having a reinforcing portion covering the reinforcing opening on the radially inner surface and a conduit portion adjacent to the plurality of cooling openings on the radially inner surface; and removing the first and second sacrificial elements to form a conduit within the conduit and a channel within the track, wherein the conduit and the conduit are connected by the plurality of cooling openings, and further forming a reinforcing member formed by a portion of the conduit and the track and covering the reinforcing opening. Attached Figure Description

[0006] The complete and implementable disclosure of this description, including its best mode, is set forth in the specification with reference to the accompanying drawings, wherein:

[0007] Figure 1 It is a schematic cross-sectional view of a gas turbine engine used in an aircraft, including its casing;

[0008] Figure 2 yes Figure 1 A perspective view of the heat exchanger of a gas turbine engine, including a set of pipes, a set of rails, a set of reinforcements and a support plate;

[0009] Figure 3 It is along Figure 2 A perspective view of the heat exchanger taken at section III-III, which further shows the corresponding reinforcement;

[0010] Figure 4 It is along Figure 1 A portion of the casing of the gas turbine engine is set Figure 2 A perspective view of the heat exchanger shown;

[0011] Figure 5 It has the following characteristics: Figure 2 A schematic diagram of an electrodeposition bath in the form of a heat exchanger mold, the mold comprising a first set of mandrels, a second set of mandrels, and a support plate;

[0012] Figure 6 yes Figure 4 A perspective view of the mold;

[0013] Figure 7 yes Figure 5An exploded perspective view of the mold, which further shows a set of tabs and a set of receivers;

[0014] Figure 8 Used in forming an exemplary heat exchanger Figure 4 A perspective view of an exemplary mold;

[0015] Figure 9 It is formed Figure 2 Methods for heat exchangers. Detailed Implementation

[0016] This disclosure relates to a heat exchanger for a turbine engine, specifically a gas turbine engine, and a method of forming the heat exchanger. The heat exchanger may include ducts or loops. Specifically, the duct may be in the form of a set of pipes defining a first interior. A set of rails supports the pipes relative to a portion of the turbine engine and defines a second interior. A support plate may be positioned between the pipes and the rails. The set of pipes, the set of rails, and the support plate may together define an integral thermal barrier. It should be understood that this disclosure relates to a heat exchanger located on a radially outer portion of an engine housing. The heat exchanger and the engine housing together may define an active clearance control (ACC) system. As used herein, an ACC system may refer to a portion of a gas turbine engine that can be used to change or maintain the clearance or distance between stationary components or stator and rotating components or rotor of the gas turbine engine. This minimizes the amount of leakage fluid flowing between the rotor and stator. As a non-limiting example, the stationary component may be a radially inner portion of the ACC system, such as the engine housing, while the rotating component may be rotating blades within the gas turbine engine.

[0017] The methods disclosed herein provide an additive manufacturing process for forming heat exchangers. Specifically, the heat exchanger can be formed by an electrodeposition manufacturing process (e.g., by electroforming). Therefore, this disclosure relates to a method of electroforming a heat exchanger that can be used in an ACC system. For illustrative purposes, an exemplary environment in which a heat exchanger can be utilized will be described in the form of a turbine engine. In a non-limiting example, such a turbine engine may be in the form of a gas turbine engine with a power gearbox, a turboprop engine, a turboshaft engine, or a turbofan engine. However, it should be understood that the aspects of this disclosure described herein are not limited thereto and can have general applicability in other heat exchangers. For example, this disclosure may be applicable to heat exchangers in other engines or vehicles and can be used to provide benefits in industrial, commercial, and residential applications.

[0018] As used herein, the term "upstream" refers to the direction opposite to the direction of fluid flow, and the term "downstream" refers to the direction in the same direction as the direction of fluid flow. The terms "front" or "forward" indicate being in front of something, and "back" or "rear" indicate being behind something. For example, when used in relation to fluid flow, front / forward can indicate upstream, and back / rear can indicate downstream.

[0019] Additionally, as used herein, the term "radial" or "radially" refers to a direction away from a common center. For example, in the context of a turbine engine as a whole, radial refers to the direction of a ray extending between the engine's central longitudinal axis and its outer perimeter. Furthermore, as used herein, the term "group" or "set" of elements can refer to any number of elements, including a single element.

[0020] All directional references (e.g., radial, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise) are used for identification purposes only to aid the reader in understanding this disclosure and do not impose limitations, particularly regarding their location, orientation, or purpose. Connection references (e.g., attachment, coupling, connection, and engagement) should be interpreted broadly and may include intermediate members between a series of elements and relative movement between elements, unless otherwise stated. Therefore, a connection reference does not necessarily imply that two elements are directly connected and fixed to each other. Exemplary figures are for illustrative purposes only, and the dimensions, positions, order, and relative sizes reflected in the accompanying figures may vary. As used herein, a “set” may include any number of elements, including a single element. As used herein, “monolithic monolith” or “monolithic body” means a single, inseparable unit or a unit formed as a single piece during manufacturing, not a unit formed during manufacturing by combining individual elements into one.

[0021] Figure 1 This is a schematic cross-sectional view of a turbine engine, specifically a gas turbine engine 10, for use in an aircraft. The gas turbine engine 10 has a generally longitudinally extending axis, or engine centerline 12, extending between the front side 14 and the rear side 16 of the gas turbine engine 10. The gas turbine engine 10 includes, in downstream series flow relationship, a fan section 18 including a fan 20, a compressor section 22 including a boost or low-pressure (LP) compressor 24 and a high-pressure (HP) compressor 26, a combustion section 28 including a combustion chamber 30, a turbine section 32 including an HP turbine 34 and an LP turbine 36, and an exhaust section 38. The gas turbine engine 10 described herein is a non-limiting example, and other architectures are possible, such as, but not limited to, steam turbine engines, supercritical carbon dioxide turbine engines, or any other suitable turbine engine.

[0022] Fan section 18 includes a fan housing 40 surrounding fan 20. Fan 20 includes a set of fan blades 42 arranged radially around engine centerline 12. HP compressor 26, combustion chamber 30, and HP turbine 34 form engine core 44 of gas turbine engine 10, which produces combustion gases. Engine core 44 is surrounded by engine housing 46, which is connectable to fan housing 40.

[0023] An HP shaft or rotating shaft 48, coaxially arranged around the engine centerline 12 of the gas turbine engine 10, drives the HP turbine 34 to the HP compressor 26. An LP shaft or rotating shaft 50, coaxially arranged around the engine centerline 12 of the gas turbine engine 10 within a larger diameter annular HP rotating shaft 48, drives the LP turbine 36 to the LP compressor 24 and the fan 20. The rotating shafts 48 and 50 are rotatable around the engine centerline 12 and are coupled to a set of rotatable elements that collectively define a rotor 51.

[0024] LP compressor 24 and HP compressor 26 each include a set of compressor stages 52, 54, in which a set of compressor blades 56, 58 rotate relative to a corresponding set of static compressor guide vanes 60, 62 (also referred to as nozzles) to compress or pressurize the fluid flow through the stage. In a single compressor stage 52, 54, multiple compressor blades 56, 58 may be arranged in a ring and may extend radially outward from the blade platform relative to the engine centerline 12 to the blade tips, while the corresponding static compressor guide vanes 60, 62 are positioned upstream of and adjacent to the rotating blades 56, 58. It should be noted that... Figure 1 The number of blades, guide vanes, and compressor stages shown is chosen for illustrative purposes only, and other numbers are possible.

[0025] Blades 56 and 58 for the first-stage compressor can be mounted to a disc 61, which is mounted to a corresponding one of the HP shaft 48 and LP shaft 50, with each stage having its own disc 61. Guide vanes 60 and 62 for the first-stage compressor can be mounted to the engine housing 46 in a circumferential arrangement.

[0026] HP turbine 34 and LP turbine 36 each include a set of turbine stages 64, 66, in which a set of turbine blades 68, 70 rotates relative to a corresponding set of static turbine guide vanes 72, 74 (also referred to as nozzles) to extract energy from the fluid flow passing through the stage. In a single turbine stage 64, 66, multiple turbine blades 68, 70 may be arranged in a ring and may extend radially outward from the blade platform relative to the engine centerline 12 to the blade tips, while the corresponding static turbine guide vanes 72, 74 are positioned upstream of and adjacent to the rotating blades 68, 70. It should be noted that... Figure 1The number of blades, guide vanes, and turbine stages shown is chosen for illustrative purposes only, and other numbers are possible.

[0027] Blades 68 and 70 for the first-stage turbine can be mounted to a disc 71, which is mounted to a corresponding one of the HP shaft 48 and LP shaft 50, with each stage having a dedicated disc 71. Guide vanes 72 and 74 for the first-stage compressor can be mounted to the engine housing 46 in a circumferential arrangement.

[0028] As a complement to the rotor section, the stationary parts of the gas turbine engine 10 (e.g., the static guide vanes 60, 62, 72, 74 in the compressor section 22 and turbine section 32) are also referred to individually or collectively as the stator 63. Therefore, the stator 63 can refer to the combination of the non-rotating elements of the entire gas turbine engine 10.

[0029] During operation, the airflow leaving fan section 18 is split, such that a portion of the airflow is directed to LP compressor 24, which then supplies pressurized airflow 76 to HP compressor 26, which further pressurizes the air. The pressurized airflow 76 from HP compressor 26 mixes with fuel in combustion chamber 30 and is ignited, producing combustion gases. HP turbine 34, driving HP compressor 26, extracts some work from these gases. The combustion gases are discharged to LP turbine 36, which extracts additional work to drive LP compressor 24, and the discharged gases are ultimately exited from gas turbine engine 10 via discharge section 38. The drive of LP turbine 36 drives LP shaft 50 to rotate fan 20 and LP compressor 24. The pressurized airflow 76 and combustion gases together define the working airflow flowing through fan section 18, compressor section 22, combustion chamber section 28, and turbine section 32 of gas turbine engine 10.

[0030] A portion of the pressurized airflow 76 can be drawn from the compressor section 22 as bleed air 77. Bleed air 77 can be drawn from the pressurized airflow 76 and supplied to engine components requiring cooling. The temperature of the pressurized airflow 76 entering the combustion chamber 30 increases significantly. Therefore, cooling provided by the bleed air 77 is necessary for the operation of such engine components in high-temperature environments.

[0031] The remainder of the airflow 78 bypasses the LP compressor 24 and the engine core 44, and exits the gas turbine engine 10 at the fan exhaust side 84 via a fixed row of guide vanes, and more particularly via an outlet guide vane assembly 80 comprising a set of airfoil guide vanes 82. More specifically, a radially extending row of circumferential airfoil guide vanes 82 is used near the fan section 18 to exert some directional control on the airflow 78.

[0032] Some of the air supplied by fan 20 can bypass engine core 44 and be used to cool portions of the gas turbine engine 10, particularly the hot parts, and / or to cool other aspects of the aircraft or to power it. In the context of a turbine engine, the hot parts of the engine are typically downstream of combustion chamber 30, particularly turbine section 32, with HP turbine 34 being the hottest part as it is directly downstream of combustion section 28. Other sources of cooling fluid may be, but are not limited to, fluid discharged from LP compressor 24 or HP compressor 26.

[0033] Figure 2 It is located in Figure 1 A perspective view of a heat exchanger 100 within a gas turbine engine 10. As shown, the heat exchanger 100 extends circumferentially around the engine centerline 12 and defines a radius of curvature in the circumferential direction. In other words, the heat exchanger 100 may be curved. However, it should be understood that the heat exchanger 100 may extend across any suitable plane or otherwise not include the curve shown. In other words, the heat exchanger 100 may be non-curved or otherwise extend linearly in any direction. The heat exchanger 100 may be located within any suitable portion of the gas turbine engine 10, such as, but not limited to, the LP compressor 24, HP compressor 26, HP turbine 34, LP turbine 36, or fan section 18.

[0034] The heat exchanger 100 may include a set of pipes 102, a set of rails 104, and a support plate 106 defined by a radially outer surface 108 and a radially inner surface 110 opposite to the radially outer surface 108. The support plate 106 may be disposed between the set of pipes 102 and the set of rails 104. Specifically, the set of pipes 102 may be disposed along a portion of the radially outer surface 108, and the set of rails 104 may be disposed along a portion of the radially inner surface 110. The set of pipes 102 and the set of rails 104 may be operatively coupled to the support plate 106. As shown, the set of pipes 102 may include two axially displaced pipes 102, and the set of rails 104 may include two axially displaced rails 104 corresponding to the two pipes 102. However, it should be understood that the heat exchanger 100 may include any number of one or more pipes 102 or any number of one or more rails 104 corresponding to the pipes 102.

[0035] The set of pipes 102 can extend circumferentially from one distal end 112, specifically circumferentially distal end 112, to another distal end. Each of the pipes 102 may include an outer wall defining an internal fluid conduit 114. A set of openings 116 to the internal fluid conduit 114 may be provided at either distal end 112. It is conceivable that the distal end 112 of the pipe 102 may be coupled to a corresponding distal end 112 of an adjacent heat exchanger 100 or to another part of the gas turbine engine 10 (e.g., a coolant circuit). Thus, one or more heat exchangers 100 can be daisy-chained together, and the distal ends 112 of the pipes 102 can serve as physical connections. It should be understood that any number of adjacent heat exchangers 100 or segmented heat exchangers 100 extending around at least a portion of the radial outer periphery of the engine core 44 may exist. Alternatively, the heat exchangers 100 may be formed as a continuous loop extending around the entire radial outer periphery. Adjacent heat exchangers 100 may be connected by any suitable coupling method, such as, but not limited to, bonding, fastening, welding, or any combination thereof. A set of features 113 extending outward from conduit 102 may be circumferentially disposed near at least one of the distal ends 112. In a non-limiting example, feature 113 may be defined as threads configured to connect conduit 102 to an additional component (e.g., a coolant circuit) having corresponding threads. Alternatively, feature 113 may be a set of seals configured to seal the internal fluid conduit 114 from a portion of the fluid outside conduit 102.

[0036] Similar to the set of pipes 102, the set of tracks 104 may extend in the circumferential direction. As a non-limiting example, the set of tracks 104 may extend circumferentially between the distal ends 112 of the set of pipes 102. A set of circumferential ends defining the circumferentially distal portions of the set of tracks 104 may be defined by plates extending radially and axially. In other words, the set of tracks 104 may close at any circumferential distal end. Each track 104 may include a set of fingers 120 that are displaced from each other and extend radially from the radially inner surface 110 of the support plate. As shown, each track 104 may include three fingers 120 of different sizes. The largest finger 120 in the set of fingers 120 may be defined by a maximum thickness 122 in the axial direction. Furthermore, each of the fingers 120 may be axially spaced from each other, such that a gap 124 is formed between two adjacent fingers 120. It should be understood that the maximum thickness 122, the number of slits 124, or the number of fingers 120 can vary among the tracks 104. For example, an exemplary track 104 may include three fingers 120 of different sizes, while adjacent tracks 104 may include a single finger 120. A set of outlets 127 may be disposed along the exterior of the set of tracks 104. The set of outlets 127 may be displaced radially, circumferentially, or axially along the exterior of the set of tracks 104 defined by the outer walls of the set of fingers 120. It should be understood that any number of one or more outlets 127 may be present along the set of tracks 104. It should also be understood that each finger 120 may include the same number of outlets 127. Alternatively, a finger 120 may have a different number of outlets 127 than another finger 120 in different axial, circumferential, or radial locations.

[0037] The support plate 106 may include a set of openings 126 disposed along at least a portion of the support plate 106 and extending between a radially inner surface 110 and a radially outer surface 108. As shown, the set of openings 126 may be oval or elliptical; however, it should be understood that they may take any form, such as, but not limited to, circular, polygonal, or any combination thereof. The support plate 106 may also include an additional opening 132 formed within a portion of the support plate 106 and extending between the radially inner surface 110 and the radially outer surface 108. The additional opening 132 may be rectangular and larger than the set of openings 126.

[0038] The support plate 106 may also include a bracket 128 that extends axially forward relative to the set of pipes 102 and the set of rails 104 from the axially forward portion of the support plate 106. The bracket 128 may extend radially from the axially forward portion of the support plate and is configured to be mounted as part of the engine housing 46, thereby mounting the entire heat exchanger 100 to the engine housing 46. The bracket 128 may be mounted to the engine housing 46 by any suitable coupling method, such as, but not limited to, bonding, welding, fastening, etc. The bracket 128 may also include a cutout 130 to remove unwanted material from the support plate 106. Thus, the cutout 130 may be defined as a weight-reduction hole or without material. For example, if the portion of the support plate 106 defined by the cutout 130 is filled with material, the total weight of the support plate 106 will be heavier than if the cutout 130 is not filled with material. Furthermore, the cutout 130 may be used to improve the manufacturability of the support plate 106. As a non-limiting example, the support plate 106 may be formed as a flat sheet that is subsequently bent to have a curvature as shown. The support 128 can be further bent so that it extends perpendicularly from the radially outer surface 108 of the support plate 106. The cut 106 makes it easier to bend the support 128 into place compared to a support 128 that includes material but is not defined by the cut 130.

[0039] The heat exchanger 100 may further include a reinforcement 134 that passes through at least a portion of the set of pipes 102 or the set of tracks 104 in a direction transverse to the engine centerline 12. As a non-limiting example, the reinforcement 134 may be formed from a portion of the set of pipes 102 and the set of tracks 104 and cover an additional opening 132. Thus, the additional opening 132 may be referred to as the reinforcement opening 132. The reinforcement 134 may define a gap connecting to the reinforcement opening 132. The gap of the reinforcement 134 may extend relative to the engine centerline 12 in at least one of axial, circumferential, or radial directions. As a non-limiting example, the reinforcement 134 may be formed as a single structure such that the reinforcement 134 defines a continuous material extending between the set of pipes 102, through the reinforcement opening 132, and into the set of tracks 104. Thus, the reinforcement 134 may further define a physical connection between the set of pipes 102 and the set of tracks 104. As shown in the figure, the reinforcing member 134 may be cylindrical, having an oval or elliptical cross-sectional area when viewed in a plane perpendicular to the engine centerline 12. However, it should be understood that the reinforcing member 134 may be formed in any suitable shape, such as, but not limited to, a circle, a polygon, or any combination thereof. For example, when viewed in a plane perpendicular to the engine centerline 12, the reinforcing member 134 may define a rectangular prism with a rectangular cross-section.

[0040] The heat exchanger 100 can be formed by an electrodeposition manufacturing process, specifically by electroforming. However, it should be understood that only the set of pipes 102, the set of rails 104, and the reinforcement 134 include portions formed by electroforming. In other words, the set of pipes 102, the set of rails 104, the support plate 106, and the reinforcement 134 can be defined as a set of electroformed pipes 102, a set of electroformed rails 104, and an electroformed reinforcement 134, each of which includes an electroformed portion.

[0041] As shown in the figure, the heat exchanger 100 may include two pipes 102 and two corresponding rails 104. However, it should be understood that the heat exchanger 100 may include any number of pipes 102 and rails 104. Furthermore, the number of pipes 102 may be greater than, equal to or less than the number of rails 104.

[0042] Figure 3 It is along Figure 2 The figure shows a perspective view of the heat exchanger 100 taken at section III-III. As shown, the reinforcement 134 may coincide with the edge of the reinforcement opening 132 of the support plate 106 and extend through the entire pipe 102 and track 104.

[0043] As shown, the set of tracks 104 may include an outer wall defining an internal channel 118. Each finger 120 may define a separate and discrete portion of the internal channel 118. The set of openings 126 may be provided along a portion of the support plate 106 corresponding to the internal fluid conduit 114 of the set of pipes 102 and the internal channel 118 defined by the set of tracks 104. The set of openings 126 may fluidly connect the internal fluid conduit 114 to the internal channel 118. The set of outlets 127 may be fluidly connected to the internal channel 118 of the set of tracks 104. The set of outlets 127 may be used to discharge fluid from inside the heat exchanger 100 to the outside of the heat exchanger 100, specifically, radially inward from the radially inner surface 110 of the support plate 106. Thus, the outlets 127 may define a set of discharge outlets for the set of tracks 104 and the heat exchanger 100. As shown, the set of outlets 127 can be formed as circular through holes within the set of tracks 104, extending from the radially inner wall facing the internal channel 118 and the radially outer wall facing the exterior of the heat exchanger 100. However, it should be understood that the outlets 127 can be formed as any suitable outlet and include any suitable geometry, such as, but not limited to, oval, rectangular, polygonal, or any combination thereof.

[0044] The reinforcing member 134 may also be defined by a first portion 136 and a second portion 138. The first portion 136 may be formed within a portion of the conduit 102, while the second portion 138 may be formed within a portion of the track 104. As shown, the first portion 136 and the second portion 138 may extend into the internal fluid conduit 114 and the internal channel 118, respectively. Thus, the portion of the conduit 102 defined by the first portion 136 and the portion of the track 104 defined by the second portion 138 may be further defined by regions with reduced cross-sectional areas. The first portion 136 and the second portion 138 may meet at the reinforcing member opening 132. It should be understood that the first portion 136 and the second portion 138 may be defined by a single metal piece, such that the first portion 136 and the second portion 138 are integrally formed, and the reinforcing member 134 physically connects the set of conduits 102 to the set of tracks 104. The support plate 106 can be sandwiched between the set of pipes 102 and the set of rails 104, so the set of pipes 102, the set of rails 104 and the support plate 106 can be connected to each other by the reinforcing member 134.

[0045] Figure 4 It shows Figure 2 The heat exchanger 100 shown is Figure 1 The gas turbine engine has an engine housing 46. It should be understood that the heat exchanger 100 may be disposed along any portion of the engine housing 46 within the gas turbine engine 10. Although shown as engine housing 46, it should be understood that the heat exchanger 100 may face any suitable housing, such as, but not limited to, engine housing 46 or fan housing 40. Therefore, the heat exchanger 100 may be disposed within the fan section 18 of the gas turbine engine 10. The engine housing 46 may enclose at least a portion of the engine core 44 and is bent to define the outer periphery of the engine core 44. As shown, the heat exchanger 100 may follow the curvature of the engine housing 46 in the circumferential direction, such that the heat exchanger 100 extends around at least a portion of the engine housing 46 and the engine core 44.

[0046] The engine housing 46 may be defined by a radially inner surface 142 and a radially outer surface 144, the radially outer surface being opposite to and radially displaced from the radially inner surface 142. A heat exchanger 100 may face at least a portion of the radially outer surface 144. In other words, at least a portion of the heat exchanger 100 may physically contact, face, be coupled to, or otherwise face the radially outer surface 144 of the engine housing 46. Specifically, the set of rails 104 may face the radially outer surface 144 of the engine housing 46.

[0047] The heat exchanger 100 can be mounted to a portion of the engine housing 46 via a connection between the engine housing 46 and the bracket 128. As shown, a set of plates 129 may extend radially outward from the radially outer surface 144 of the engine housing 46 and face at least a portion of the bracket 128. The bracket can then be mounted to the plates 129 by any suitable method, such as, but not limited to, welding, bonding, fastening, magnetism, or combinations thereof. Although shown as discrete plates 129, it should be understood that the bracket 128 may be mounted to any suitable portion of the engine housing 46. For example, the bracket 128 may be mounted to the front wall of the engine housing 46, which extends circumferentially around the entire engine housing 46. In this case, two brackets 128 may be mounted to the same portion (e.g., the front wall) of the engine housing 46.

[0048] It should be understood that the engine housing 46, specifically the radially inner surface 142 of the engine housing 46, may face a portion of the working airflow 98, or otherwise face a set of rotating blades of the engine core 44 (e.g., compressor blades 56, 58, turbine blades 68, 70, or fan blades 42) and the engine housing 46. As used herein, the working airflow 98 may refer to any suitable airflow within the gas turbine engine 10, such as, but not limited to, pressurized airflow 76, bleed air 77, airflow 78, combustion gases within the turbine section 32, or any other suitable airflow within the gas turbine engine 10. As shown, at least a portion of the heat exchanger 100 may extend transversely to the engine centerline 12 or the working airflow 98.

[0049] A set of protrusions 146 may extend radially outward from a radially outer surface 144 and otherwise define a portion of the radially outer surface 144. The set of protrusions 146 may correspond to a gap 124 between a set of fingers 120 of a set of tracks 104. The set of protrusions 146 may extend parallel to the set of tracks 104 along the entire circumferential length of the fingers 120 in the gap 124 between adjacent fingers 120. Alternatively, the set of protrusions 146 may extend only along a portion of the circumferential length of the set of tracks 104, such that a portion of the gap 124 between adjacent fingers 120 is not filled by the set of protrusions 146 along the entire radial extent of the fingers 120. The set of protrusions 146 may be further defined as a feature of the engine housing 46. Thus, a portion of the set of protrusions 146 may be defined by a region 148 of the set of protrusions having an increased width. This ensures that the surface area (axial, radial, and circumferential) of the set of protrusions 146 facing the set of fingers 120 is maximized. As shown, the set of tracks 104 can be formed with varying circumferential lengths to accommodate these regions 148 with increased width. Therefore, the gap 124 and maximum thickness 122 of the set of fingers 120 can be sized based on the spacing of the set of protrusions 146. As shown, a space can be formed between the protrusions 146 and the set of fingers 120 such that the protrusions 146 do not physically contact the fingers 120. However, it is conceivable that one or more portions of the protrusions 146 may physically contact at least a portion of the fingers 120.

[0050] It is further conceivable that the set of protrusions 146 may extend radially across any portion of the gap between adjacent fingers 120. As shown, the set of protrusions 146 does not extend radially through at least some of the outlets 127. Furthermore, the reinforcement 134 may be radially displaced from the engine housing 46 such that the reinforcement 134 extends transversely to the working airflow 98.

[0051] During operation of the gas turbine engine 10, a working airflow 98 may flow through a portion of the gas turbine engine 10, specifically through the engine core 44. The working airflow 98 may vary in temperature depending on its position within the engine core 44. For example, the working airflow downstream of the combustion section 28 within the HP turbine 34 may reach temperatures as high as 1500°C. As the working airflow 98 flows through the engine core 44, the engine housing 46 may be heated by the working airflow 98 or otherwise absorb at least a portion of the heat from the working airflow. This heat may then be transferred from the radially inner surface 142 facing the engine core 44 or the working airflow 98 to the radially outer surface 144. The heat may then be radiated radially outward from the radially outer surface 144 of the engine housing 46. The heat exchanger 100 may act as a thermal barrier between the heat radiated outward from the engine housing 46 and the radially outward portion of the gas turbine engine 10 from the heat exchanger 100 (e.g., but not limited to electronics, seals, or other suitable components that may be susceptible to the high heat of the working airflow 98).

[0052] Furthermore, the heat exchanger 100 can cool at least a portion of the engine housing 46. For example, at least a portion of the heat exchanger 100, specifically the internal fluid conduit 114, can be directly fluidly connected to a coolant source, allowing coolant to flow through the internal fluid conduit 114, through the opening 116 of the support plate 106, and into the internal passage 118 of the set of rails 104. The coolant can be any suitable coolant, such as, but not limited to, bleed air 77, bypass air, liquid coolant, or any other suitable coolant. At least a portion of the coolant within the rails 104 can be discharged through the set of outlets 127 and impinge on at least a portion of the engine housing 46. The coolant discharged from outlet 127 can define a cooling fluid 192. As a non-limiting example, the cooling fluid 192 can impinge on the radially outer surface 144 of the engine housing 46. The coolant within the rails 104 and therefore the cooling fluid 192 can have a lower temperature than the working airflow 98. Therefore, the cooling fluid 192 can be used to cool the engine housing 46. The remaining coolant within heat exchanger 100 can then be transferred to internal fluid conduit 114 and circulated out of heat exchanger 100. As a non-limiting example, the coolant circulated out of heat exchanger 100 may be combined with fluid within discharge section 38. Alternatively, heat exchanger 100 may be fluidly coupled to a coolant circuit, such that coolant within heat exchanger 100 circulates out of heat exchanger 100, is cooled (e.g., via another heat exchanger or air conditioning system), and then circulates back into heat exchanger 100.

[0053] The heat exchanger 100 and the engine housing 46 together define the ACC system. As described above, during operation of the gas turbine engine 10, coolant within the heat exchanger 100, specifically within the internal passage 118 of the track 104, can be discharged from outlet 127 and impact a portion of the engine housing 46. The cooling fluid 192 may have a lower temperature than the operating airflow 98, such that the cooling fluid 192 can cool the engine housing 46. When the engine housing 46 is heated by the operating airflow 98, the engine housing 46 may expand radially outward relative to the engine centerline 12. However, the cooling fluid 192 can counteract the expansion of the engine housing 46 by cooling the engine housing 46, thereby eliminating the radial expansion of the engine housing 46. This, in turn, maintains the radial space or clearance between the radially inner surface 142 of the engine housing 46 and the corresponding rotating blades. As a non-limiting example, the cooling fluid 192 can be used to contract the engine housing 46, thereby reducing the clearance between the radially inner surface 142 and the rotating blades. In either case, the ACC system can expand or contract according to the operating conditions of the gas turbine engine, allowing the space or clearance between the tip and the radially internal portion of the ACC system (e.g., the radially inner surface 142 of the engine housing 46) to vary. The ACC system can dynamically control the clearance between the engine housing 46 and the rotating blades, which can ultimately reduce the amount of working airflow 98, defined as a leakage airflow, that can flow radially around the rotating blades. It is conceivable that the greater the amount of leakage airflow present within the gas turbine engine 10, the less efficient the rotating blades are in generating work, because the leakage airflow does not contact the rotating blades and generate torque. The ACC system can minimize the amount of leakage airflow or maximize the amount of working airflow 98, thereby improving the overall performance of the gas turbine engine 10.

[0054] During operation of the gas turbine engine 10, pressurization of fluids (e.g., working airflow 98) within the engine core 44 can generate forces on the heat exchanger 100. As a non-limiting example, pressurization can apply circumferential stresses to the engine housing 46 and the heat exchanger 100, extending radially, circumferentially, and axially around the engine housing 46 and the heat exchanger 100. As previously described, a reinforcement 134 can physically connect the set of pipes 102 to the set of rails 104. Therefore, the reinforcement 134 can uniformly distribute the circumferential stresses across the set of pipes 102, the set of rails 104, and the plate 156, thereby reducing the effect of the circumferential stresses on any individual portion of the heat exchanger 100. In other words, the reinforcement 134 can counteract the circumferential stresses. As used herein, the term "counteract" can be defined as the ability of a component (e.g., heat exchanger 100) to withstand or otherwise adapt to forces applied to that component.

[0055] Figure 5 It is used to form by electrodeposition bath 140 and mold 158 Figure 2 A schematic diagram of the electroforming process of the heat exchanger 100. An exemplary bath 150 carries a conductive electrolytic fluid solution 152. In one non-limiting example, the electrolytic fluid solution 152 may include an aluminum alloy carrying alloy metal ions. In an alternative non-limiting example, the electrolytic fluid solution 152 may include a nickel alloy carrying alloy metal ions.

[0056] An anode 154, spaced apart from a mold 158, is disposed in a bath 150. The mold 158 may include a set of cathodes. This set of cathodes may be disposed via a set of conduits 102 (…). Figure 2 The first set of spindles 160 in the shape of ) and the set of tracks 104 ( Figure 2 The second set of mandrels 162 in the shape of ) and the bearing plate 106 ( Figure 2 The bath 150 is defined by a plate 156 in the shape of a conductive material. The anode 154 can be a sacrificial anode or an inert anode. While one anode 154 is shown, it should be understood that the bath 150 may include any number of anodes 154 as needed. As a non-limiting example, the first set of mandrels 160 and the second set of mandrels 162 may comprise a non-conductive material. Since the materials of the first set of mandrels 160 and the second set of mandrels 162 are non-conductive, they may be coated with a conductive material, such as, but not limited to, a carbonaceous coating. Alternatively, the conductive material may be any other suitable coating, such as, but not limited to, copper, silver, or nickel. It is further envisioned that the first set of mandrels 160 and the second set of mandrels 162 may be recyclable materials that can be collected after the electroforming process and reused in future electroforming processes. The first set of mandrels 160 and the second set of mandrels 162 may comprise materials such as, but not limited to, wax, plastic, polymer foam, metal, deformable materials, or any combination thereof. The first set of mandrels 160 and the second set of mandrels 162 may include material that can be collected (e.g., removed) by melting, burning, or leaching. As shown, both the first set of mandrels 160 and the second set of mandrels 162 include two corresponding mandrels 160, 162. Therefore, the mold 158 can be used to form a heat exchanger 100 having two pipes 102, two tracks 104, and a plate 156 disposed therebetween. However, it should be understood that any number of one or more mandrels 160 may be present in the first set of mandrels 160 and any corresponding number of mandrels 162 may be present in the second set of mandrels 162.

[0057] During the electroforming process, a metal layer is deposited along any portion of the mold 158 that defines the set of cathodes and exposes it to the electrolytic fluid solution 152. As a non-limiting example, the exterior of the first set of mandrels 160, the exterior of the second set of mandrels 162, and the exterior of the plate 156 may be covered by the metal layer, thereby forming the set of conduits 102, the set of tracks 104, and the support plate 106 of the heat exchanger 100, respectively. After the electroforming process is completed, the first set of mandrels 160 and the second set of mandrels 162 may be recovered from the electroformed component or otherwise removed by any suitable method (e.g., but not limited to heating, melting, burning, leaching, or any other suitable method). Because the first set of mandrels 160 and the second set of mandrels 162 are removed or otherwise sacrificed after the electroforming process, the first set of mandrels 160 may be defined as a first sacrificial element, and the second set of mandrels 162 may be defined as a second sacrificial element.

[0058] Conversely, no portion of the support plate 106 is sacrificed or otherwise removed by heating, melting, burning, or leaching. Therefore, the support plate 106 can be defined as a non-sacrificial element. The support plate 106 may comprise, for example, but not limited to, nickel-chromium-based alloys, stainless steel alloys (e.g., stainless steel 305), or any other suitable material.

[0059] A controller 164, which may include a power supply, may be electrically connected to an anode 154 and a mold 158, specifically the set of cathodes, via a set of electrical conduits 166 to form a circuit 167 via an electrolytic fluid solution 152. A switch 168 or sub-controller may be included along the electrical conduits 166 and may be positioned between the controller 164 and the anode 154 and the mold 158, specifically the set of cathodes. During operation, current may be supplied from the anode 154 to the mold 158, specifically the set of cathodes, via the electrolytic fluid solution 152, along an outer electroformed metal layer of a first set of mandrels 160 and a second set of mandrels 162 coated with a carbonaceous coating. The metal layer may be any suitable metal, such as, but not limited to, aluminum, iron, cobalt, nickel, or any combination thereof.

[0060] The pump (P) and filter (F) can be used to filter the electrolytic fluid solution 152 and chemically maintain the electrolytic fluid solution 152 at a specific ion concentration, or to remove any foreign matter. As a non-limiting example, the filter (F) may include a chemical filter medium. A heater (H) is provided to regulate the temperature of the electrodeposition bath 140. In a non-limiting example, the heater (H) may be located inside the bath 150 or outside the bath 150 near the bath 150. Alternatively, the heater (H) may be in fluid communication with the pump (P) to heat the electrolytic fluid solution 152 as it is pumped by the pump (P).

[0061] Figure 6 yes Figure 4A perspective view of a mold 158, which includes a first set of mandrels 160 and a second set of mandrels 162 and a plate 156 disposed therebetween. As previously described, mold 158 may include a first set of mandrels 160 defining a set of conduits 102, a second set of mandrels 162 defining a set of tracks 104, and a plate 156 disposed therebetween and defining a support plate 106. As a non-limiting example, the first set of mandrels 160 may define an internal fluid conduit 114 of the set of conduits 102, and a metal layer disposed on the exterior of the first set of mandrels 160 may define an external body of the set of conduits 102. The second set of mandrels 162 may define an internal channel 118 of the set of tracks 104, and a metal layer disposed on the exterior of the second set of mandrels 162 may define an external body of the set of tracks 104. The plate 156 and the metal layer disposed on the exterior of the plate 156 together may define the support plate 106.

[0062] Plate 156 may extend between a radially inner surface 186 and a radially outer surface 188, the outer surface being opposite to and displaced from the radially inner surface 188. An opening 190 may extend through a portion of plate 156. For example, opening 190 may extend between the radially inner surface 186 and the radially outer surface 188. A protrusion 193 may extend outward from and perpendicular to the radially outer surface 188. Protrusion 193 may have a cutout 194 or be without material.

[0063] A first set of spindles 160 may extend between a set of first distal ends 170. A set of features 172 may be disposed near the set of first distal ends 170 and extend outward from the first set of spindles 160. A second set of spindles 162 may coincide with the first set of spindles 160 such that the second set of spindles 162 extends between a set of second distal ends 174, wherein at least one of the second distal ends 174 corresponds to at least one of the first distal ends 170 of the first spindles 160.

[0064] The first set of spindles 160 may include a first reinforcing feature 176, while the second set of spindles 162 may include a second reinforcing feature 178 consistent with the first reinforcing feature 176. The first reinforcing feature 176 and the second reinforcing feature 178 may cover the opening 190 of the plate 156.

[0065] The second set of mandrels 162 may also include a set of finger portions 180 extending outward from the inner surface 186 of the plate 156. As shown, each second mandrel 162 may have three finger portions 180; however, it should be understood that each second mandrel 162 may have any number of one or more finger portions 180.

[0066] During the electroforming process, everything along the first set of mandrels 160 and the second set of mandrels 162 can be covered with a carbonaceous coating, thereby depositing a metal layer along the entire first set of mandrels 160 and the second set of mandrels 162. Once the first set of mandrels 160 and the second set of mandrels 162 are removed, only the metal layer remains. As described herein, plate 156 may be defined as a cathode. As a non-limiting example, plate 156 may be defined as a non-sacrificial mandrel having a conductive material. Therefore, the features of the first set of mandrels 160, the second set of mandrels 162, and plate 156 described herein can be used with heat exchanger 100 ( Figure 2 The first distal end 170, the first feature 172, and the first reinforcing feature 176 may correspond to the distal end 112, feature 113, and first portion 136 of the conduit 102, respectively, while the remaining body of the second mandrel 162 may define at least a portion of the internal fluid conduit 114. The finger portion 180 and the second reinforcing feature 178 may correspond to the finger portion 120 and the second portion 138, respectively, while the body of the second mandrel 162 may define an internal channel 118. The radial inner surface 188, the radial outer surface 188, the opening 190, the protrusion 193, and the cut 194 may correspond to the radial inner surface 108, the radial outer surface 110, the reinforcing opening 132, the support 128, and the cut 130 of the support plate 106, respectively.

[0067] After the electroforming process and the removal of the sacrificial element, additional processing can be performed to form various portions of the heat exchanger 100. For example, additional processing can be performed to form outlet 127 or opening 116. Processing can be accomplished by any suitable processing procedure, such as, but not limited to, drilling, chiseling, cutting, or any combination thereof. Alternatively, it is conceivable that one or more portions of the first set of mandrels 160 or the second set of mandrels 162 are not covered with carbonaceous coating, thus eliminating the need for additional processing. Therefore, after the electroforming process, the metal layer may be discontinuous on the first set of mandrels 160 and the second set of mandrels 162, thus defining areas of mandrels 160, 162 without a metal layer. As a non-limiting example, at least a portion of the first set of distal ends 170 or at least a portion of the second set of distal ends 174 may be without carbonaceous coating, such that openings (e.g., the set of openings 116) are formed into the internal fluid conduit 114 and the internal channel 118, respectively.

[0068] Figure 7 yes Figure 4 An exploded view of mold 158, which includes a first set of mandrels 160 and a second set of mandrels 162 and a plate 156 disposed between them.

[0069] It should be understood that during the electroforming process, a portion of plate 156 is covered by the first set of mandrels 160 and the second set of mandrels 162. Therefore, a portion of plate 156 will not be exposed to the electrolytic fluid solution 152, meaning that a metal layer will not be formed on the portion of plate 156 not exposed to the electrolytic fluid solution 152. As a non-limiting example, plate 156 may include the same set of openings 126 that support plate 106. These openings 126 may be covered by the first set of mandrels 160 and the second set of mandrels 162, such that a metal layer does not form on or around these openings 126.

[0070] A set of tabs 182 located on the second set of spindles 162 may extend outward from the second set of spindles 162 and correspond to at least some of the openings 126 of the plate 156. In other words, the set of tabs 182 may coincide with at least some of the openings 126 of the support plate 106 and be formed such that the set of tabs 182 may extend through at least some of the openings 126 of the support plate 106.

[0071] A set of receivers 184 located on the first set of mandrels 160 may extend into a portion of the first set of mandrels. This set of receivers 184 may correspond to a set of tabs 182, such that for each tab 182, there is a corresponding receiver 184. The receivers 184 may be sized such that the tabs 182 can fit within the receivers 184. The tabs 182 and receivers 184 physically connect the first set of mandrels 160 to the second set of mandrels 162, wherein a support plate 106 may be disposed between them.

[0072] Figure 8 It is used to form something similar to heat exchanger 100 ( Figure 2 This is a perspective view of an exemplary mold 258 of an exemplary heat exchanger. Mold 258 is similar to mold 158; therefore, similar parts will be identified using similar numerals in the 200 series, and it should be understood that, unless otherwise stated, the description of similar parts of mold 158 applies to exemplary mold 258.

[0073] The mold 258 includes a first mandrel 260 and a second mandrel 262 and a plate 256 disposed therebetween. The plate 256 extends from a radially inner surface 286 to a radially outer surface 288.

[0074] The first mandrel 260 and the second mandrel 262 may be similar to the first set of mandrels 160 and the second set of mandrels 162, except that the first mandrel 260 and the second mandrel 262 consist of only a single first mandrel 260 and a single second mandrel 262 corresponding to the first mandrel 260. Therefore, the mold 258 may form an exemplary heat exchanger having a single conduit 102 and a single track 104. A set of features 272 may be disposed along at least one distal end of a set of first distal ends 270 and extend outward from the first mandrel 260. The first mandrel 260 may also include a first reinforcing feature 276.

[0075] The second spindle 262 may extend between a set of second distal ends 274, wherein at least one of the second distal ends 274 circumferentially corresponds to at least one first distal end 270 of the first spindle 260. The second spindle 262 may also include a second reinforcing feature 278 and a set of finger portions 280.

[0076] Plate 256 may be similar to plate 156, except that plate 156 may have a different length compared to plate 156. As a non-limiting example, plate 256 may be defined as a shortened plate 256 compared to plate 156. Unlike plate 156, plate 256 does not include the protrusion 193, therefore the support plate 106 formed by mold 258 does not include the bracket 128. Mold 258 may be used where only a portion of the heat exchanger 100 is required.

[0077] Figure 9 It is through the use of Figure 5 Mold 158 electroforming Figure 2 Method 300 for heat exchanger 100. Although described in terms of heat exchanger 100 and mold 158, it should be understood that method 300 can be applied to any suitable heat exchanger, for example using Figure 7 An exemplary heat exchanger formed by mold 258.

[0078] At 302, method 300 may begin by electroforming at least one conduit 102 onto at least one first mandrel 160 carried by plate 156. As previously described, the first mandrel 160 may be a sacrificial mandrel or a first sacrificial element, while plate 156 may be a non-sacrificial element. The non-sacrificial element or plate 156 may include an opening 190 corresponding to a reinforcement opening 132, and the set of openings 126 or cooling openings extending between a radially inner surface 186 and a radially outer surface 188. The first sacrificial element or first mandrel 160 may include a first reinforcement feature 176 corresponding to a first portion 136 of reinforcement 134, which covers the opening 190 corresponding to the reinforcement opening 132 on the radially outer surface 188. The body of the first mandrel 160, which at least partially defines the internal fluid conduit 114, may abut the set of openings 126 on the radially outer surface 188 of the non-sacrificial element. At 304, at least one track 104 corresponding to at least one conduit 102 can be electroformed on at least one second mandrel 162 carried by plate 156. As previously described, the second mandrel 162 can be a sacrificial mandrel or a second sacrificial element. The second sacrificial element may include a second reinforcing feature 278 corresponding to a second portion 138 of reinforcing element 134. The second reinforcing feature 278 and thus the second portion 138 may cover the opening 190 on the radially inner surface 186 of the non-sacrificial element. The body of the second mandrel 162, which at least partially defines the internal passage 118, may abut the set of openings 126 on the radially inner surface 186 of the non-sacrificial element. At 306, the first and second sacrificial elements can be removed to define the internal fluid conduit 114 within conduit 102 and the internal passage 118 within track 104, respectively. The internal fluid conduit 114 can be fluidly connected to the internal passage 118 through the set of openings 126. The reinforcing element 134 may be formed by a physical connection between the first portion 136 and the second portion 138.

[0079] The order described is for illustrative purposes only and is not intended to limit method 300 in any way, as it should be understood that parts of the method may be performed in different logical orders, may include additional or intervening parts, or the described part of the method may be divided into multiple parts, or the described part of the method may be omitted without diminishing the described method. For example, method 300 may include various other steps.

[0080] In a non-limiting example, method 300 may also include electroforming a support plate 106 on plate 156. As described herein, plate 156 may be defined as a non-sacrificial element because it is not removed after the electroforming process. Thus, plate 156 and the metal layer deposited on plate 156 together form support plate 106. Plate 156 or non-sacrificial element may include the set of openings 190 and the set of openings 126 corresponding to the reinforcing opening 132.

[0081] In another non-limiting example, method 300 may also include: at 306, during the process of removing the first sacrificial element and the second sacrificial element, at least one of burning, melting, heating, leaching, or any other combination thereof, on the first sacrificial element and the second sacrificial element.

[0082] In yet another non-limiting example, method 300 may further include aligning the second sacrificial element with plate 156 such that at least one of the set of tabs 182 extends from the radially inner surface 186 through an opening 126 in plate 156 to the radially outer surface 188. Method 300 may further include aligning at least one of the tabs 182 extending through at least one of the openings 126 with at least one of the set of receivers 184 such that at least one tab 182 extends into at least one corresponding receiver 184, thereby coupling the first sacrificial element to the second sacrificial element, wherein plate 156 is disposed between them.

[0083] In yet another non-limiting example, method 300 may further include coating at least a portion of the first and second sacrificial elements with a conductive coating (e.g., a carbonaceous coating) such that the first and second sacrificial elements define the set of cathodes or cathode layers. The coating may be performed by any suitable method, such as, but not limited to, smearing, spraying, immersion, or any combination thereof. Method 300 may also include removing the cathode layer using an etchant, which may be any suitable etchant, such as, but not limited to, acetone.

[0084] In yet another non-limiting example, method 300 may also include machining at least a portion of the heat exchanger 100 after electroforming has occurred. For example, method 300 may include machining an outlet 127 within the set of rails 104 by drilling or cutting. As yet another non-limiting example, method 300 may include machining the set of openings 116 of the set of pipes 102 by drilling or cutting.

[0085] The benefits of this disclosure include a method for forming a heat exchanger without the need for conventional connection methods required in conventional heat exchangers. As a non-limiting example, the benefits of this disclosure include a method for forming a heat exchanger for an ACC system without the need for conventional connection methods required when forming a conventional heat exchanger for a conventional ACC system. For example, conventional heat exchangers, such as those found in conventional ACC systems, comprise a set of rails, a set of pipes, and a plate disposed between them. The rails, pipes, and plates are prefabricated components that need to be physically connected to each other by various methods (e.g., welding, bonding, fastening, etc.). These points where the prefabricated components are physically connected to each other can create points along a conventional heat exchanger that may be more prone to failure due to the use of the heat exchanger. For example, during the operation of a gas turbine engine, a conventional heat exchanger may be subjected to forces (e.g., circumferential stress) or indirect exposure to high heat (e.g., heat radiated from the engine casing), which may ultimately lead to failure at the connection points. This, in turn, can negatively impact the expected lifespan of the conventional heat exchanger. However, heat exchangers that can be used in ACC systems as described herein do not use conventional connection methods. Instead, heat exchangers as described herein are additively manufactured via electrodeposition, specifically electroforming. This additive manufacturing process eliminates areas of physical bonding that would otherwise be potential failure points in conventional heat exchangers. Therefore, heat exchangers as described herein can have a longer expected lifespan and are better suited to the forces and heat within turbine engines than conventional heat exchangers.

[0086] Another benefit of this disclosure includes a heat exchanger that better withstands the forces applied to it during turbine engine operation compared to conventional heat exchangers. As a non-limiting example, the benefit of this disclosure includes a heat exchanger for an ACC system that better withstands the forces applied to it compared to conventional heat exchangers used in conventional ACC systems. For example, a conventional heat exchanger includes a set of pipes and a set of rails that are continuous and uniform throughout their circumferential direction. This, in turn, makes the conventional heat exchanger susceptible to various stresses that will be applied to it during turbine engine operation, such as circumferential stresses imposed on the heat exchanger by the pressure of the working airflow. However, a heat exchanger that can be used in an ACC system includes a set of stiffeners disposed along the set of pipes and the set of rails, the stiffeners extending through stiffener openings in a support plate and physically connecting the set of rails to the set of pipes. The stiffeners reduce circumferential stresses within the set of rails, the support plate, and the set of pipes by distributing circumferential forces along the heat exchanger. Compared to conventional heat exchangers, this reduces the heat exchanger's sensitivity to the forces applied to it during turbine engine operation. This ultimately improves the heat exchanger's efficiency and lifespan.

[0087] Another benefit of this disclosure includes a heat exchanger that is lighter and minimizes waste compared to conventional heat exchangers. As a non-limiting example, another benefit of this disclosure includes a heat exchanger for an ACC system that is lighter and minimizes waste compared to conventional heat exchangers for conventional ACC systems. For example, as described above, conventional heat exchangers rely on prefabricated components in their construction. In a heat exchanger with two or more pipes and rails, the pipes and rails can be formed as a single prefabricated component, such that material spans the distance between adjacent pipes or rails. Alternatively, two or more rails or two or more pipes can be formed as separate pieces, each requiring physical connection to a plate in some way, shape, or form. Additionally, the pipes and rails of a conventional heat exchanger require physical connection to a support plate. All of this adds additional material to the assembly, which in turn increases the overall weight of the conventional heat exchanger. However, the heat exchanger described herein is formed by additive manufacturing and includes the set of reinforcements connecting the set of rails and the set of pipes as described above. Furthermore, a monolithic metal layer is deposited throughout the first set of mandrels, the second set of mandrels, and the plate. This means that each component of the heat exchanger is formed as a single metal piece and is therefore interconnected. In other words, there is no need to connect adjacent pipes or rails to each other or to the support plate. Compared to conventional heat exchangers, this ultimately reduces the total material required to form the heat exchanger. Furthermore, the support plate bracket includes cutouts, while conventional brackets do not. This further eliminates the additional material required to form the heat exchanger. Ultimately, the heat exchanger described herein is lighter than a conventional heat exchanger. This, in turn, reduces the overall weight of the turbine engine, thereby improving the turbine engine's efficiency compared to conventional turbine engines.

[0088] Within the scope not yet described, different features and structures of the various aspects may be combined with each other as needed. The fact that a feature cannot be shown in all aspects does not mean it cannot be interpreted as such, but rather for the sake of brevity. Therefore, various features of different aspects may be mixed and matched as needed to form new examples, whether or not these new examples are explicitly described. This disclosure covers combinations or arrangements of the features described herein. In addition to the embodiments and constructions shown in the foregoing figures, this disclosure contemplates many other possible embodiments and constructions.

[0089] This written description uses examples to illustrate aspects of the disclosure described herein, including best practices, and also enables any person skilled in the art to practice aspects of the disclosure, including making and using any device or system and performing any incorporated methods. The patentability scope of aspects of this disclosure is defined by the claims and may include other examples that would occur to a person skilled in the art. Such other examples are intended to fall within the scope of the claims if they include structural elements that are not indistinguishable from the literal language of the claims, or if they include equivalent structural elements that are not substantially indistinguishable from the literal language of the claims.

[0090] Further aspects of this disclosure are provided by the subject matter of the following provisions:

[0091] An electroformed heat exchanger suitable for use in a turbine engine having an engine centerline includes: an electroformed support plate having a radially outer surface and a radially inner surface, a reinforcing opening extending between the radially inner surface and the radially outer surface, and a plurality of cooling openings extending between the radially inner surface and the radially outer surface; an electroformed pipe having an internal fluid conduit fluidly connected to the plurality of cooling openings; an electroformed rail having at least one internal channel fluidly connected to the plurality of cooling openings, wherein the internal channel is fluidly connected to the internal fluid conduit through the plurality of cooling openings; and an electroformed reinforcing member formed by a portion of the electroformed pipe and the electroformed rail and covering the reinforcing opening.

[0092] According to any of the foregoing clauses, in an electroformed heat exchanger, an electroformed reinforcement operatively connects an electroformed conduit to an electroformed track.

[0093] According to any of the foregoing clauses, the electroformed heat exchanger wherein the electroformed reinforcement defines a gap extending axially relative to the engine centerline, the gap being connected to an opening in the reinforcement.

[0094] An electroformed heat exchanger according to any of the foregoing clauses, wherein internal fluid conduits and internal channels extend circumferentially around the engine centerline.

[0095] According to any of the foregoing clauses, in an electroformed heat exchanger, the reinforcing member extends generally transversely to the direction of fluid flow within at least one of the internal fluid conduits or internal channels.

[0096] An electroformed heat exchanger according to any of the foregoing clauses, wherein the electroformed heat exchanger comprises a plurality of circumferentially arranged sections.

[0097] According to any of the foregoing clauses, the electroformed heat exchanger, when viewed in a plane perpendicular to the engine centerline, defines an oval cross-section.

[0098] An electroformed heat exchanger according to any of the foregoing clauses, wherein the electroformed heat exchanger is disposed along a portion of a fixed housing of a turbine engine, and wherein the fixed housing further includes a radially inner surface facing the working airflow of the turbine engine and a radially outer surface opposite to the radially inner surface, wherein the electroformed heat exchanger is disposed along a portion of the radially outer surface.

[0099] According to any of the foregoing clauses, the electroformed heat exchanger includes a set of protrusions extending radially outward from the radially outer surface relative to the engine centerline, and an electroformed track fits onto the set of protrusions.

[0100] According to any of the foregoing clauses, the electroformed heat exchanger includes a set of fingers extending radially away from the electroformed support plate, the set of fingers being axially displaced relative to each other, having a slit defining a space between adjacent fingers, and wherein the set of protrusions engages within the slit.

[0101] An electroformed heat exchanger according to any of the foregoing clauses, wherein the electroformed pipes are included within a set of axially spaced electroformed pipes, and the electroformed rails are included within a set of axially spaced electroformed rails corresponding to the set of axially spaced electroformed pipes.

[0102] According to any of the foregoing clauses, the electroformed heat exchanger further includes a bracket extending radially outward relative to the engine centerline, and wherein the bracket is connected to at least a portion of the turbine engine.

[0103] An electroformed heat exchanger according to any of the foregoing clauses, wherein the electroformed heat exchanger is disposed within the high-pressure turbine section of a turbine engine.

[0104] A method for electroforming a heat exchanger suitable for use in a turbine engine having an engine centerline, the method comprising: electroforming a conduit on a first sacrificial element supported by a non-sacrificial support plate having a radially outer surface and a radially inner surface, a reinforcing opening extending between the radially inner surface and the radially outer surface, and a plurality of cooling openings extending between the radially inner surface and the radially outer surface, the first sacrificial element having a reinforcing portion covering the reinforcing opening on the radially outer surface and a conduit portion adjacent to the plurality of cooling openings on the radially outer surface; electroforming a track on a second sacrificial element, the second sacrificial element having a reinforcing portion covering the reinforcing opening on the radially inner surface and a conduit portion adjacent to the plurality of cooling openings on the radially inner surface; and removing the first and second sacrificial elements to form a conduit within the conduit and a channel within the track, wherein the conduit and the conduit are connected by the plurality of cooling openings, and further forming a reinforcing member formed by a portion of the conduit and the track and covering the reinforcing opening.

[0105] The method according to any of the foregoing clauses further includes electroforming a non-sacrificial bearing plate on the non-sacrificial element, the non-sacrificial element having an opening corresponding to the opening of the reinforcement.

[0106] The method according to any of the foregoing clauses, wherein the removal of the first sacrificial element and the second sacrificial element includes at least one of melting, burning, heating or leaching the first sacrificial element and the second sacrificial element.

[0107] The method according to any of the foregoing provisions, wherein the first sacrificial element includes at least one receiver, and the second sacrificial element includes at least one protrusion corresponding to at least one receiver.

[0108] The method according to any of the foregoing clauses further includes aligning at least one tab with at least one of the plurality of cooling openings such that at least one tab extends through at least one cooling opening.

[0109] The method according to any of the foregoing clauses further includes aligning at least one receiver with at least one protrusion.

[0110] The method according to any of the foregoing clauses further includes coating at least a portion of the first sacrificial element and the second sacrificial element with a carbonaceous coating to define a cathode layer.

Claims

1. An electroformed heat exchanger adapted for use within a turbine engine having an engine centerline, the electroformed heat exchanger comprising: an electroformed carrier plate having a radially outer surface and a radially inner surface, a stiffener opening extending between the radially inner surface and the radially outer surface, and a plurality of cooling openings extending between the radially inner surface and the radially outer surface; an electroformed duct having an internal fluid conduit fluidly coupled to the plurality of cooling openings; an electroformed rail having at least one internal passage fluidly coupled to the plurality of cooling openings, wherein the internal passage is fluidly coupled to the internal fluid conduit through the plurality of cooling openings; and an electroformed stiffener formed from a portion of the electroformed duct and the electroformed rail and covering the stiffener opening. The electroformed stiffener operably couples the electroformed duct to the electroformed rail.

2. The electroformed heat exchanger of claim 1, wherein, The electroformed stiffener defines a void extending axially relative to the engine centerline, the void coupled to the stiffener opening.

3. The electroformed heat exchanger of claim 1, wherein, The internal fluid conduit and internal passage extend circumferentially about the engine centerline.

4. The electroformed heat exchanger of claim 1, wherein, The stiffener extends generally transverse to a direction of fluid flow within at least one of the internal fluid conduit or the internal passage.

5. The electroformed heat exchanger of claim 1, wherein, The electroformed heat exchanger includes a plurality of circumferentially arranged segments.

6. The electroformed heat exchanger of claim 1, wherein, The electroformed stiffener defines an oval cross-section when viewed in a plane perpendicular to the engine centerline.

7. The electroformed heat exchanger of claim 1, wherein, The electroformed heat exchanger is disposed along a portion of a stationary casing of the turbine engine, and wherein the stationary casing further includes a radially inner surface facing a working air flow of the turbine engine and a radially outer surface opposite the radially inner surface, wherein the electroformed heat exchanger is disposed along a portion of the radially outer surface.

8. The electroformed heat exchanger of any one of claims 1 to 7, wherein, The stationary casing includes a set of protrusions extending radially outward from the radially outer surface relative to the engine centerline, and the electroformed rail fits over the set of protrusions.

9. The electroformed heat exchanger of claim 8, wherein, The electroformed rail includes a set of fingers extending radially away from the electroformed carrier plate, the set of fingers axially displaced relative to one another with interstices defining spaces between adjacent fingers, and wherein the set of protrusions fit within the interstices.

10. The electroformed heat exchanger of claim 9, wherein, The electroformed duct is included within a set of axially spaced apart electroformed ducts, and the electroformed rail is included within a set of axially spaced apart electroformed rails corresponding to the set of axially spaced apart electroformed ducts.

11. The electroformed heat exchanger of any one of claims 1 to 8, wherein, The electroformed carrier plate further includes a brace extending radially outward relative to the engine centerline, and wherein the brace is coupled to at least a portion of the turbine engine.

12. The electroformed heat exchanger of any one of claims 1 to 8, wherein, The electroformed heat exchanger is disposed within a high pressure turbine section of the turbine engine.

13. The electroformed heat exchanger of any one of claims 1 to 8, wherein, 14. A method of electroforming a heat exchanger adapted for use within a turbine engine having an engine centerline, the method comprising: ​ electroforming a conduit on a first sacrificial element carried by a non-sacrificial carrier plate having a radially outer surface and a radially inner surface, with a stiffener opening extending between the radially inner surface and the radially outer surface and a plurality of cooling openings extending between the radially inner surface and the radially outer surface, and the first sacrificial element having a stiffener portion covering the stiffener opening on the radially outer surface and a conduit portion abutting the plurality of cooling openings on the radially outer surface; electroforming a rail on a second sacrificial element, the second sacrificial element having a stiffener portion covering the stiffener opening on the radially inner surface and a conduit portion abutting the plurality of cooling openings on the radially inner surface; and removing the first and second sacrificial elements to form a conduit within the conduit and a channel within the rail, wherein the conduit and rail are connected by the plurality of cooling openings, and further forming a stiffener formed from a portion of the conduit and rail and covering the stiffener opening.

15. The method of claim 14, further comprising electroforming the non-sacrificial carrier plate on a non-sacrificial element having an opening corresponding to the stiffener opening.

16. The method of any one of claims 14-15, wherein, The removing of the first sacrificial element and the second sacrificial element includes at least one of melting, burning, heating, or leaching the first sacrificial element and the second sacrificial element.

17. The method of any one of claims 14-15, wherein, The first sacrificial element includes at least one receiver and the second sacrificial element includes at least one tab corresponding to the at least one receiver.

18. The method of claim 17, further comprising aligning the at least one tab with at least one of the plurality of cooling openings such that the at least one tab extends through the at least one cooling opening.

19. The method of claim 18, further comprising aligning the at least one receiver with the at least one tab.

20. The method of any one of claims 14 to 15, further comprising coating at least a portion of the first sacrificial element and the second sacrificial element with a carbonaceous coating to define a cathode layer.

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