Our products : Robust construction
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Construction

Diffusion-bonded heat exchangers are constructed from flat metal plates into which fluid flow channels are either chemically etched or pressed. The required configuration of the channels on the plates for each fluid is governed by the temperature and pressure-drop constraints for the heat exchange duty and the channels can be of unlimited variety and complexity. Fluid contact can be counterflow, crossflow, co-flow or a combination of these to suit the process requirements.  

etched plates

 pressed plates


Plates are then stacked and diffusion-bonded together to form strong, compact, all-metal heat exchange cores. Diffusion-bonding is a "solid-state joining" process entailing pressing metal surfaces together at temperatures below the melting point, thereby promoting grain growth between the surfaces. Under carefully controlled conditions, diffusion-bonded joints reach parent metal strength and stacks of plates are converted into solid blocks containing the fluid flow passages. The blocks are then welded together to form the complete heat exchange core.

stacked plates

    micrograph


Finally, fluid headers and nozzles are welded to the core in order to direct the fluids to the appropriate sets of passages. No gaskets or braze material - potential sources of leakage, fluid incompatibility and temperature limitations - are required for exchanger assembly. Mechanical design is normally to ASME VIII Division 1. Other design codes can be employed as required.

completed exchanger


Animated Construction Sequence Video

Click here to download the animated construction sequence.

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Materials of construction

The majority of diffusion-bonded heat exchangers are constructed from 300 series stainless steel.

Various other metals are compatible with the diffusion-bonded process and have been qualified for use. These include:

- 22 chrome duplex  
- copper
- nickel
- nickel alloys
- titanium


In addition, we are continually expanding this list to meet emerging requirements.
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Titanium exchanger

0.5MW, 40 bar gas cooler in titanium
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0.5MW, 40 bar gas cooler.

Titanium exchangers are supplied where seawater cooling is used.
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Nickel exchanger

Nickel PCHE
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Nickel exchangers installed on caustic soda evaporation plant.
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