Patent ID: 8646178

Claim:
A method for fabricating a heat exchanger, the method comprising: providing a metal body defining a bore extending through the metal body, the bore comprising a plurality of rectilinear bore sections, wherein an inlet hydraulic connector is fitted to the body at an inlet end of the bore and an outlet hydraulic connector is fitted to the body at an outlet end of the bore, the inlet hydraulic connector and the outlet hydraulic connector each comprising an inner surface in which a plurality of annular grooves is formed; inserting a tube into the bore such that the tube is surrounded by a wall of the body defining the bore, the tube comprising a plurality of rectilinear tube sections, wherein an inlet end of the tube is located in the inlet hydraulic connector and an outlet end of the tube is located in the outlet hydraulic connector, and wherein inserting the tube into the bore comprises inserting the tube sections into corresponding bore sections; operating a mandrel to expand at least a portion of the tube into contact with the wall, to expand the inlet end of the tube into contact with the inner surface and the annular grooves of the inlet hydraulic connector and to expand the outlet end of the tube into contact with the inner surface and the annular grooves of the outlet hydraulic connector, forming a fluid-tight connection between the tube and the inlet hydraulic connector and between the tube and the outlet hydraulic connector; connecting the tube sections in series by joints to establish a fluid flow path from one tube section to another tube section via the corresponding joint, each joint comprising a joint opening open to an outer surface of the body; and closing each joint opening by installing a respective closing member at the joint opening.