# US 10,766,097 B2 · Integration of ultrasonic additive manufactured thermal structures in brazements

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- Number: US 10,766,097 B2
- Document ID: US10766097B2
- Status: Granted
- Kind: B2
- Application number: 15/486,724
- Filed: 2017-04-13
- Published: 2018-10-18
- Granted: 2020-09-08
- Earliest claimed: 2017-04-13
- Assignees: Raytheon Company
- Applicants: Raytheon Company
- Inventors: Travis L. Mayberry; James A. Pruett; Craig H. McCordic; David H. Altman
- Web page: https://patentgrep.com/patent/US10766097B2

## CPC

- B23K 20/10: making use of vibrations, e.g. ultrasonic welding
- B23K 20/103: {using a roller}
- B23K 20/106: {Features related to sonotrodes}
- B23K 20/22: taking account of the properties of the materials to be welded
- B23K 20/2336: {both layers being aluminium}
- B23P 15/26: heat exchangers {or the like (making heat exchangers by methods covered by other subclasses B21D53/02)}
- B33Y 10/00: Processes of additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- F28D 9/0081: {the conduits for one heat-exchange medium being formed by a single plate-like element (F28D9/0012 takes precedence); the conduits for one heat-exchange medium being integrated in one single plate-like element (F28D9/0012 takes precedence)}
- F28F 3/02: Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations (F28F3/08 takes precedence)
- F28F 3/04: the means being integral with the element
- F28F 3/048: {in the form of ribs integral with the element or local variations in thickness of the element, e.g. grooves, microchannels}
- F28F 3/06: the means being attachable to the element
- F28F 3/08: Elements constructed for building-up into stacks, e.g. capable of being taken apart for cleaning
- F28F 3/12: Elements constructed in the shape of a hollow panel, e.g. with channels {(F28D1/02, F28D1/03 take precedence)}
- F28F 9/02: Header boxes; End plates
- F28F 21/08: of metal
- F28F 21/084: {from aluminium or aluminium alloys}
- H05K 7/20163: {the components being isolated from air flow, e.g. hollow heat sinks, wind tunnels or funnels}
- H05K 7/20254: {Cold plates transferring heat from heat source to coolant}
- B23K 2101/14: Heat exchangers
- B23K 2103/10: Aluminium or alloys thereof
- F28F 21/085: {from copper or copper alloys}
- F28F 2250/106: with cross flow
- F28F 2255/00: Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
- F28F 2255/06: composite, e.g. polymers with fillers or fibres
- F28F 2275/04: by brazing
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23P: METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS (arrangements for copying or controlling B23Q)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- F28D: HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT (fluid heaters having heat generating means and heat transferring means F24H; furnaces F27; details of heat-exchange apparatus of general)
- F28F: DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION (water and air traps, air venting F16)
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS

## Abstract

A manifold structure has at least one flow passage and a center manifold section that has at least one machined cavity. The manifold structure includes a plurality of ultrasonically additively manufactured (UAM) finstock layers arranged in the flow passage. After the finstock is formed by UAM, the finstock is permanently joined to the center manifold section via a brazing or welding process. Using UAM and a permanent joining process enables joining of the UAM finstock having enhanced thermal features to a vacuum brazement structure. UAM enables the finstock to be formed of dissimilar metal materials or multi-material laminate materials. UAM also enables bond joints of the finstock to be arranged at angles greater than ten degrees relative to a horizontal axis by using the same aluminum material in the UAM process and in the vacuum brazing process.

## Claims

### Claim 1

A manifold structure having at least one flow passage, the manifold structure comprising:
a center manifold section formed of a single metal material and having at least one machined cavity in communication with the at least one flow passage; and
a plurality of ultrasonic additively manufactured finstock layers that are arranged within the flow passage and segment the flow passage into a plurality of flow cavities,
wherein the finstock layers are stacked in a direction normal to the center manifold section and permanently joined to the center manifold section, the finstock layers being vacuum brazed to the center manifold section, and
wherein the finstock layers are formed of a multi-material laminate material having dissimilar metal materials that is integrated into the single metal material of the center manifold section and
wherein each of the finstock layers has a bond joint that is a point of contact between a sheet of the respective finstock layer and a vertically extending support wall of the manifold structure, wherein the bond joint of at least one of the finstock layers is arranged at an angle greater than ten degrees relative to a horizontal axis of the manifold structure.

### Claim 2 (depends on 1)

The manifold structure of claim 1, wherein the dissimilar metal materials includes at least one material that is a same material as the single metal material of the center manifold section.

### Claim 3 (depends on 2)

The manifold structure of claim 2, wherein the same material is an aluminum material.

### Claim 4 (depends on 3)

The manifold structure of claim 3, wherein the multi-material laminate material further includes at least one of copper, molybdenum, tungsten, titanium, or silicon carbide.

### Claim 5 (depends on 1)

The manifold structure of claim 1, wherein the center manifold section is formed of aluminum.

### Claim 6 (depends on 1)

The manifold structure of claim 1, wherein the finstock layers are formed of aluminum and at least one second material that is embedded within the aluminum.

### Claim 7 (depends on 6)

The manifold structure of claim 6, wherein the at least one second material is copper, molybdenum, tungsten, titanium, or silicon carbide.

### Claim 8 (depends on 1)

The manifold structure of claim 1, wherein the manifold structure is a heat exchanger.