Key constraints: compact envelope, high-pressure helium, and zero on-site adjustment.

The client required a compact, high-performance heat exchanger for use in high-temperature industrial heat pumps, capable of operating with high-pressure helium while fitting precisely within a very limited pump housing, leaving no room for on-site adjustments. To ensure long-term reliability, a wide range of design requirements had to be verified during the development phase. 

Prior to manufacturing, the design underwent detailed FEA simulations to confirm its structural integrity under demanding operating conditions. One of the key challenges was achieving fully helium leak-tight joints. Another critical objective was to ensure that the design could be efficiently scaled for series production of multiple units to meet future demand.

Additionally, the design had to remain manufacturable and repeatable to support future series production.

To meet strict geometric requirements, the assembled tube pack had to be CNC-machined to its final dimensions using a sequence of manufacturing stages and dedicated tooling developed specifically for this project.

This enabled all critical operations to be performed in-house with full process control, consistent product quality, and dimensional verification using specialized equipment.

To minimize deformation and significantly increase the stiffness of the tube-to-tubesheet joints, vacuum brazing was selected as the joining method, requiring an extremely accurate fit between the tubes and tubesheet holes. The filler material fully penetrates the joint across the entire tubesheet thickness, eliminating gaps and mitigating the risk of crevice corrosion.

Additionally, the process enables high production efficiency, as multiple units can be brazed in a single cycle, supporting scalable series production and capacity for future orders.

The final design was validated through comprehensive FEA simulations and full-scale proof testing, including hydrostatic pressure tests and helium leak tests — all performed in-house at AIC S.A.

Key outcomes: leak-tight performance, precise fit, and installation-ready delivery.

The result was a highly reliable, ready-to-install tube pack assembly that met all technical and spatial requirements. The exchanger demonstrated excellent helium leak-tight performance, allowing the heat pump to operate safely at elevated pressures and temperatures.

Additionally, the compact form factor enabled seamless integration into the pump housing without on-site adjustments. Moreover, the precise manufacturing and validation process ensured zero rework during installation, highlighting the robustness of our engineering approach and quality-assurance framework.

This project exemplifies our expertise in delivering engineered-to-order heat exchangers for demanding industrial applications, combining precision machining, advanced vacuum brazing, and stringent quality assurance to produce compact, high-efficiency thermal solutions for high-pressure gases and high-temperature water systems.