Aluminum extrusions are ideal for this application because they provide the ability to create complex shapes with multiple voids at a reasonable cost. Aluminum is lightweight, has a high thermal conductivity, and performs well in harsh environments. The extrusion process is the only viable technology to fabricate a long heat exchanger, of this type, cost effectively.
This component was produced using a 6105T6 alloy. The exterior features were designed into the extrusion and are used for tie-rods holding the end plates/manifolds, pump, etc. to the unit.