Hybrid Fluid-Flow Fitting Assembly

A fluid-flow assembly kit, comprising:

• a) a base fluid flow fitting that has been formed by axial load bulge forming from a sheet of metal, having an input port, at least one output port, and a fluid flow channel connecting said input and output ports;
• b) a plurality of custom fluid-flow fittings that have been machined from a shape memory alloy, having a parent shape, a martensitic shape, an output port, an input port having an inner diameter in its deformed condition slightly larger than said output port of the base fitting, and a fluid flow channel connecting said input and output ports;
• wherein said input port of said custom fitting is connected to the output port of the base fitting by an interference fit.

A method of making a custom fluid flow assembly, comprising the steps of:

• a) forming a base fluid flow fitting from a sheet of metal, said base fitting having an input port, at least one output port, and a fluid flow channel connecting said input and output ports;
• b) machining a custom fluid-flow fitting from a cast shaped-memory alloy, said custom fitting having a parent condition, a martensitic condition, an input port having an inner diameter larger slightly larger than at least one output port of the base fitting in the martensitic condition, at least one output port, and a fluid flow channel connecting said input and output ports;
• c) creating a mechanical connection between the base fitting and the custom fitting by installing the input port of the custom fitting over an output port of the base fitting.