Systems and methods to control fabrication of an assembly involve a first end sheet having an interior surface and an exterior surface, opposite the interior surface. A system includes interior sheets, the interior sheets including a first interior sheet at one end of a stack of the interior sheets and including a last interior sheet at an opposite end of the stack of the two or more interior sheets, the first interior sheet being adjacent to the interior surface of the first end sheet, and a second end sheet having an interior surface and an exterior surface, opposite the interior surface. The last interior sheet is adjacent to the interior surface of the last end sheet, and the interior surface of the first end sheet or the second end sheet includes venting features, the venting features including holes or slots to channel heat, gas, or vapor during a brazing process.

A plate heat exchanger has two metal plates brought into abutment, with a solder material between the plates. The plates are heated up to a first temperature. The plates are placed into a mold, the mold surfaces of which have cavities for envisaged channel structures. Channel structures are formed by local internal pressure forming of at least one plate under pressurization by the tool. The plates are heated up to a second temperature. The plates are solder bonded at the abuted surfaces. A plate heat exchanger has two metal plates, wherein channel structures have been formed in at least one plate and the plates are bonded to one another by soldering away from the channel structures. Eutectic microstructures having a longest extent of less than 50 micrometers are formed in the solder layer.

An apparatus includes a fin pack of parallel plates that protrude from a base, a lid attachable to the fin pack opposite the base, and a brazing material painted onto the lid only in a plurality of wettable regions. The lid is positioned against the fin pack, opposite the base, with portions of the plurality of regions contacting edges of the parallel plates. The lid is brazed to the fin pack without intrusion of the brazing material between the parallel plates. This is accomplished by obtaining a lid to be attached to a fin pack of parallel plates that protrude from a base, painting the lid with the brazing material only in a plurality of wettable regions, positioning the lid against the fin pack, opposite the base, with portions of the plurality of regions contacting edges of the parallel plates, and brazing the lid to the fin pack.

An enclosed heat sink with a brazed structure is provided. The enclosed heat sink with the brazed structure includes a first brazing plane formed on a top surface of a first brazing body, and a second brazing plane formed on a bottom surface of a second brazing body. The first brazing plane and the second brazing plane are pressed and brazed together, so that the first brazing body and the second brazing body enclose a cavity. A plurality of channels are formed on the first brazing plane, and each of the channels is neither perpendicular nor parallel to the first brazing plane.

A welding method for a connector and a connection tube of a heat exchanger are proposed. The method includes: forming a diffusion layer on a surface of the connector, a corrosion potential of the diffusion layer being less than a corrosion potential of the connector; inserting a connection tube into the connector; brazing the connection tube to the connector by a brazing filler metal, a corrosion potential of a weld metal formed after brazing of the brazing filler metal being higher than the corrosion potential of the connector and less than a corrosion potential of the connection tube.

A heating, ventilation, and/or air conditioning (HVAC) packaged unit includes a first refrigerant circuit component configured to change a temperature or a pressure of a refrigerant flowing through the first refrigerant circuit component and a second refrigerant circuit component configured to change a temperature or a pressure of the refrigerant flowing through the second refrigerant circuit component. The first and the second refrigerant circuit components are within a common refrigerant circuit that is disposed within a common support structure. The HVAC packaged unit also includes an interconnection conduit having a length formed from aluminum, a first end segment coupled to a first end of the length, and a second end segment coupled to a second end of the length. The first end segment and the second end segment are each formed from copper, and the interconnection conduit extends between the first refrigerant circuit component and the second refrigerant circuit component.

A method of making a heat exchanger that includes sealing tubes to header slots and brazing the tubes to the header slots. The method further includes coupling a cover to the header to cover a liquid-side surface of the header and to cover ends of the tubes, and applying flux to an air-side surface of the header and to the tubes. Coupling the cover to the header is performed after sealing the tubes to the header slots and coupling the cover to the header is performed before applying flux to the air-side surface of the header and to the tubes. Applying flux is performed before brazing each of the tubes to the header slots and sealing each of the tubes to the header slot includes sealing a perimeter of each of the tubes to the header slot.

An enclosed heat sink with a side wall structure is provided. The side wall structure includes a welding body having a first welding plane and a side wall structure having a second welding plane. The first welding plane and the second welding plane are pressured and welded to each other, such that the welding body and the side wall structure encapsulate a cavity. A width of the second welding plane is smaller than a width between two side surfaces of the side wall structure.

A tube and tubesheet assembly is provided, which includes a tubesheet, the tubesheet comprising at least one tube insertion aperture therethrough; at least one tube inserted in the at least one tube insertion aperture; and a damage-resistant layer applied to an edge of the at least one tube and along an inner surface of a portion of the tube that is positioned within the corresponding tube insertion aperture. A heat exchanger including the assembly is also provided. A method is also provided for coupling a tube to a tubesheet. The method includes applying a damage-resistant layer to an edge of the tube and along an inner surface of a portion of the tube that is positioned within a tube insertion aperture in the tubesheet. The method can also be used to repair tubes and retrofit pre-existing tube-to-tubesheet joints.

A liquid cooling head manufacturing method includes the following steps. First, a liquid channel main body is provided. Then, a heat dissipation bottom plate and a heat sink are disposed in different recessed indentations in the liquid channel main body. The heat dissipation bottom plate and the heat sink are welded in the liquid channel main body and a cover plate is sealed on the liquid channel main body.