Header arrangement for additively manufactured heat exchanger

A method of manufacturing a heat exchanger, the method comprising:

• forming a first fluid circuit by:
• forming a first set of fins that extend radially and that are coaxial with each other;
• forming a first inlet header fluidly connected to and disposed on an upstream end of the first set of fins, wherein the first inlet header comprises a circular shape;
• forming a first outlet header fluidly connected to and disposed on a downstream end of the first set of fins, wherein the first outlet header comprises a circular shape;
• forming a second fluid circuit by:
• forming, with layer-by-layer additive manufacturing, a second set of fins that extend radially and that are coaxial with each other;
• wherein:
• the first set of fins and the second set of fins form an alternating pattern in a circumferential direction such that each fin of the first set of fins is positioned between two fins of the second set of fins and each fin of the second set of fins is positioned between two fins of the first set of fins;
• forming, with layer-by-layer additive manufacturing, a second inlet header fluidly connected to and disposed on an upstream end of the second set of fins, wherein an annular shape of the second inlet header conforms to the circular shape of the first inlet header;
• and
• forming, with layer-by-layer additive manufacturing, a second outlet header fluidly connected to and disposed on a downstream end of the second set of fins, wherein an annular shape of the second outlet header conforms to the circular shape of the first outlet header.

A heat exchanger comprising:

• a first fluid circuit formed by:
• a first set of fins that extend radially and that are coaxial with each other;
• a first inlet header fluidly connected to and disposed on an upstream end of the first set of fins, wherein the first inlet header comprises a circular shape;
• and
• a first outlet header fluidly connected to and disposed on a downstream end of the first set of fins, wherein the first outlet header comprises a circular shape;
• and
• a second fluid circuit formed by:
• a second set of fins that extend radially and that are coaxial with each other;
• a second inlet header fluidly connected to and disposed on an upstream end of the second set of fins, wherein an annular shape of the second inlet header conforms to the circular shape of the first inlet header;
• and
• a second outlet header fluidly connected to and disposed on a downstream end of the second set of fins, wherein an annular shape of the second outlet header conforms to the circular shape of the first outlet header;
• a third fluid circuit formed by:
• a pass-through chamber disposed coaxial with a centerline axis of the heat exchanger;
• a third inlet header disposed on an upstream end of the pass-through chamber;
• and
• a third outlet header fluidly connected to the pass-through chamber and disposed on a downstream end of the pass-through chamber.