SADDLEBACK AEROSPACE - Compact Heat Exchangers

Saddleback's compact heat exchangers use a laminated foil construction to reduce the core size and weight of Liquid/Liquid and Liquid/Air heat exchangers.

Advantages of Laminated Foil Heat Exchangers

• Improved Thermal Performance
  • Reduced Scale of Passages Yields Higher Heat Transfer Coefficients
  • Large Heat Transfer Area Per Unit Volume
• Compact Construction
  • 5X Core Depth Reduction Compared to Conventional Concepts
  • 3X Weight Reduction
• Robust Construction
  • Laminated Foil Heat Exchangers Use a Reinforced, Robust Construction
  • Almost Any Metal Can be Used (Cu, Al, SS, Superalloys, etc.)
  • Structures Can be:
    • Soldered (Low Cost)
    • Brazed (for Aluminum)
    • Diffusion Bonded (Higher Strength, Longer Fatigue Life, Reduced Corrosion Potential)

Current/Previous Heat Exchanger Development Programs

Advanced Integrated Fuel System (Current)

Saddleback is currently under contract to Northrop/SPARTA to design and fabricate an Inconel 718 Fuel/Bleed Air heat exchanger sized to reject 14700 Btu/min. This radiator is designed to operate at extreme temperatures (~ 1000F)and internal pressures (1300 psi), and must be packaged in an extremely restricted volume. At least one prototype will be built and tested by March '96. AMITA , a partner of Saddleback, has developed the necessary superalloy fabrication processes and will be manufacturing the prototypes.

Unmanned Aerial Vehicle Heat Exchanger (1992)

Saddleback employees designed, built and tested a prototype heat exchanger for the Propulsion Engineering Directorate of the Naval Air Warfare Center. The air/engine coolant heat exchanger was designed to cool a 150 HP UAV engine, dissipating 50 HP (3300 Btu/min) of waste heat. Analytic trade studies produced a final design which was 18" x 18" x 0.5", and weighed only 5 lbs. Click HERE (69K) for a view of the 3" x 4" prototype version built for NAWC.

Advanced Amphibious Assault Vehicle Land Mode Radiator (1991)

Saddleback employees designed, built and tested a prototype radiator for David Taylor Research Center. The air/engine coolant radiator was sized to reject 28400 Btu/min. The baseline high performance aluminum radiator was 34" x 34" x 6" and weighed 217 lbs; the Saddleback version had a core depth of only 1.8" and weighed only 70 lbs. Eight subscale prototypes were built and tested, confirming the design calculations.

For more information contact:

Saddleback Aerospace
Attn: Geoff Campbell
5318 E. 2nd St., #154
Long Beach, CA 90803
(310) 930-0700
(310) 930-0031 [FAX] EMail: GEOFFCAMPBELL@SADDLE-AERO.COM
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