Cast Plate Heat Exchanger With Directional Solidification Fins

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Solution Overview

Problem

Existing heat exchangers in turbine engines face challenges in withstanding increased operational temperatures and pressures due to unbalanced thermal stresses and material limitations, limiting system-wide efficiency improvements.

Innovation Solution

A cast plate heat exchanger design featuring directional solidification casting methods to create a unitary structure with optimized fin height-to-thickness ratios, uniform wall thickness, and controlled solidification processes, enhancing thermal transfer capabilities and mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional sheet metal brazing is used to create heat exchanger plates and fins, then thermal transfer capability is achieved, but unbalanced thermal stresses develop due to temperature gradients creating high stresses in certain locations that can exceed material and assembly capabilities

Engineering Contradiction:

Improvethermal transfer capabilityVSAvoidstructural strength under thermal stress

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The invention changes the manufacturing parameter from conventional sheet metal brazing to directional solidification casting. This parameter change enables the creation of a unitary structure with controlled grain flow and uniform wall thickness, eliminating the thermal stress concentration problems inherent in brazed constructions while maintaining excellent thermal transfer capabilities through optimized fin geometry and material distribution

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention employs composite material strategies by integrating multiple functions (structural support, thermal transfer, flow distribution) into a single cast component. The directional solidification process creates a controlled composite microstructure with oriented grain patterns that provide both mechanical strength and thermal conductivity in critical directions, resolving the stress-thermal transfer contradiction

Inventive Principle:

Principle #40Composite materials

2Power

If turbine engine operational temperatures and pressures are increased to improve efficiency, then engine efficiency improves, but demands on heat exchanger components increase beyond existing material and design capabilities

Engineering Contradiction:

Improveengine efficiencyVSAvoidheat exchanger reliability under extreme conditions

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The invention changes the material processing parameters through directional solidification casting, creating a unitary structure with controlled grain flow patterns and uniform wall thickness. This enables the heat exchanger to withstand increased operational temperatures and pressures by eliminating stress concentration points and achieving more uniform stress distribution throughout the component

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The directional solidification process performs preliminary action by pre-establishing the optimal microstructure and grain orientation during manufacturing. The controlled solidification creates a predetermined grain flow pattern that anticipates and counteracts thermal stress development during operation, enabling the component to reliably withstand extreme conditions before they occur

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If conventional casting methods are used for heat exchanger components, then manufacturing is simplified, but the structure does not adequately withstand increased operational demands due to unbalanced stresses

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidwithstand capability under pressure and temperature

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention applies directional solidification casting, which changes the solidification parameters from conventional random or uncontrolled patterns to a controlled directional process. This creates a unitary structure with oriented grain patterns that follow the stress flow paths, maintaining manufacturing simplicity while dramatically improving the ability to withstand operational demands through optimized material distribution and stress distribution

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The design enables improved thermal transfer and mechanical resilience, allowing operation in extreme environments with reduced porosity and enhanced efficiency under high pressures.

Implementation Method 1

cast plate heat exchanger and method of making using directional solidification

Methodology Applied

Scientific EffectDirectional solidification: Freezing

Implementation Method 2

adjacent flow paths that transfer heat from a hot flow to a cooling flow

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12480721B2Cast plate heat exchanger and method of making using directional solidification

Publication Date: 2025.11.25 RTX CORP

AI summary

A cast part includes an outermost wall, at least one inner wall defining at least two internal passages and at least one cast cooling fin extending from an outer surface. The cast part including a cross-sectional circular area spanning at least a portion of each of four internal passages includes a ratio of interior empty space to inner wall space that improves heat transfer.