Heat exchangers play a vital role in ongoing efforts to conserve energy. Plate-type heat exchangers typically consist of two flat separated flow paths in which heat transfer enhancing matrices are inserted. The combined effects of small irregular hydraulic diameters along with elevated heat transfer areas results in highly-efficient heat transfer to the external fluid. This allows for very versatile and compact heat exchanger designs. Typical plate-type heat exchanger fabrication methods such as brazing are labour intensive and limit post-processing operations like welding. In this paper, a novel micro-heat exchanger fabrication method using recently patented technologies is presented. The approach uses thermal spray processes such as Pulsed Gas Dynamic Spraying (PGDS) as an alternative to brazing for the production of a pressure barrier and integration of flow headers. Mesh wafer surfaces sealed using PGDS

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