Internal hydroforming method for manufacturing heat pipe wicks

A method of forming a wick, comprising:

• positioning a wick mesh about an inflatable tube;
• positioning the inflatable tube and the wick mesh at least partially within a first recess defined in a first forming shell;
• positioning a second forming shell onto the first forming shell such that the inflatable tube and the wick mesh are received at least partially in a second recess defined in the second forming shell;
• coupling an end flange to the first forming shell and the second forming shell, wherein the end flange defines a hydraulic opening;
• pressurizing the inflatable tube via the hydraulic opening to press the wick mesh against the first recess and the second recess to form the wick;
• and
• removing the formed wick from the first recess and the second recess by separating the first forming shell and the second forming shell from each other;
• the method further comprising:
• positioning the inflatable tube about a porous support tube, wherein pores defined in the porous support tube are configured to fluidically couple the source of pressure to the inflatable tube;
• positioning a first o-ring, a first portion of the porous support tube, and a first portion of the inflatable tube uncaptured by the wick mesh in a first receiving area defined in the first end flange;
• and
• positioning a second o-ring, a second portion of the porous support tube, and a second portion of the inflatable tube uncaptured by the wick mesh in a second receiving area defined in the second end flange.

A method of forming a wick, comprising:

• positioning a metallic wire mesh about an expandable tube;
• positioning the expandable tube and the metallic wire mesh at least partially within a first recess defined in a first forming shell;
• positioning a second forming shell such that the expandable tube and the metallic wire mesh are at least partially received in a second recess defined in the second forming shell;
• coupling the first forming shell to the second forming shell;
• pressurizing the expandable tube to press the metallic wire mesh against the first recess and the second recess to form the wick;
• depressurizing the expandable tube;
• and
• decoupling the first forming shell from the second forming shell to remove the formed wick;
• the method further comprising:
• positioning an inflatable tube about a porous support tube, wherein pores defined in the porous support tube are configured to fluidically couple a source of pressure to the inflatable tube;
• positioning a first o-ring, a first portion of the porous support tube, and a first portion of the inflatable tube uncaptured by the wick mesh in a first receiving area defined in a first end flange;
• and
• positioning a second o-ring, a second portion of the porous support tube, and a second portion of the inflatable tube uncaptured by the wick mesh in a second receiving area defined in a second end flange.