Internal hydroforming method for manufacturing heat pipe wicks

1. A forming assembly configured to form a wick for a heat pipe, the forming assembly comprising:

an expandable tube hydraulically expandable to an expanded configuration;

a wire mesh configured to be wrapped about the expandable tube;

a forming shell assembly, comprising:

a first forming shell defining a first recess; and

a second forming shell defining a second recess, wherein the first recess and the second recess cooperate to define an inner diameter of the forming shell assembly, wherein the expandable tube and the wire mesh are positionable between the first recess and the second recess, wherein the wire mesh is configured to engage the first recess and the second recess based on the expandable tube expanding toward the expanded configuration, wherein the first recess and the second recess are configured to define an outer diameter of the wick, based on the wire mesh engaging the first recess and the second recess, and wherein the outer diameter of the wick is equal to the inner diameter of the forming shell assembly; and

an end flange configured to couple the first forming shell to the second forming shell, wherein the end flange defines a hydraulic opening, and wherein the expandable tube is configurable to hydraulically expand towards the expanded configuration based on pressure applied through the hydraulic opening by a source of pressure.

2. The forming assembly of claim 1 , wherein the wick is configured to separate from expandable tube based on the expandable tube transitioning toward an unexpanded configuration.

3. The forming assembly of claim 2 , wherein the wick is configured to separate from the expandable tube absent chemical intervention.

4. The forming assembly of claim 1 , wherein the expandable tube comprises polyurethane.

5. The forming assembly of claim 1 , further comprising a clamp plate assembly configured to clamp the first forming shell to the second forming shell, wherein the clamp plate assembly comprises:

a first clamp plate configured to abut the first forming shell;

a second clamp plate configured to abut the second forming shell; and

a fastener configured to fasten the first clamp plate to the second clamp plate.

6. The forming assembly of claim 1 , further comprising a support tube positionable within the expandable tube, wherein the support tube comprises pores defined therein, wherein the pores are configured to fluidically couple a source of pressure to the expandable tube.

7. The forming assembly of claim 1 , wherein the end flange comprises a receiving area configured to receive an o-ring and a portion of the expandable tube uncaptured by the wire mesh therein.

8. A forming assembly configured to form a wick for a heat pipe, the forming assembly comprising:

a wick assembly, comprising:

a porous support tube comprising pores defined therein; and

an inflatable tube configurable between a delated configuration and an inflated configuration, wherein the inflatable tube is positioned about the porous support tube;

a metallic wire mesh configured to be wrapped about the inflatable tube; and

a forming shell assembly, comprising:

a first forming shell defining a first recess;

a second forming shell defining a second recess, wherein the wick assembly is positionable between the first recess and the second recess, wherein the first recess and the second recess are configured to define an inner diameter of the forming shell assembly, wherein the wire mesh is configured to engage the first recess and the second recess based on the inflatable tube expanding to the inflated configuration, wherein the first recess and the second recess are configured to define an outer diameter of the wick, based on the wire mesh engaging the first recess and the second recess, and wherein the outer diameter of the wick is equal to the inner diameter of the forming shell assembly;

a first end flange couplable to the first forming shell and the second forming shell, wherein the first end flange comprises:

a first receiving area configured to receive a first o-ring, a first portion of the porous support tube, and a first portion of the inflatable tube therein; and

a hydraulic opening configured to fluidically couple a source of pressure to the inflatable tube; and

a second end flange couplable to the first forming shell and the second forming shell, wherein the second end flange comprises a second receiving area configured to receive a second o-ring, a second portion of the porous support tube, and a second portion of the inflatable tube therein.

9. The forming assembly of claim 8 , further comprising means for preventing the first forming shell and the second forming shell from separating as the inflatable tube is inflated toward the inflated configuration.

10. The forming assembly of claim 8 , wherein the inflatable tube comprises polyurethane.

11. The forming assembly of claim 8 , wherein the inflatable tube is configured to deform the wire mesh and form the wick based on the inflatable tube transitioning towards the inflated configuration.

12. The forming assembly of claim 11 , wherein the wick is configured to separate from inflatable tube absent chemical intervention.

13. A forming assembly configured to form a wick for a heat pipe, the forming assembly comprising:

an inflatable tube;

a wire mesh configured to be wrapped about the inflatable tube;

a shell assembly, comprising:

a first shell, wherein a first cavity is defined in the first shell; and

a second shell, wherein a second cavity is defined in the second shell, wherein the inflatable tube and the wire mesh are positionable between the first shell and the second shell, and wherein the first cavity and the second cavity cooperate to define an inner diameter of the shell assembly, wherein the wire mesh is configured to engage the first cavity and the second cavity based on the inflatable tube expanding toward an inflated configuration, wherein the first cavity and the second cavity are configured to define an outer diameter of the wick, based on the wire mesh engaging the first cavity and the second cavity, and wherein the outer diameter of the wick is equal to the inner diameter of the forming assembly; and

an end flange configured to couple the first shell to the second shell, wherein the end flange defines a hydraulic opening, and wherein the inflatable tube is configurable to expand towards the inflated configuration based on pressure applied through the hydraulic opening by a source of pressure.

14. The forming assembly of claim 13 , wherein the wick is configured to separate from inflatable tube based on the inflatable tube transitioning toward an uninflated configuration.

15. The forming assembly of claim 14 , wherein the wick is configured to separate from inflatable tube absent chemical intervention.

16. The forming assembly of claim 13 , wherein the inflatable tube comprises polyurethane.

17. The forming assembly of claim 13 , further comprising a clamp plate assembly configured to clamp the first shell to the second shell, wherein the clamp plate assembly comprises:

a first clamp plate configured to abut the first shell;

a second clamp plate configured to abut the second shell; and

a fastener configured to fasten the first clamp plate to the second clamp plate.

18. The forming assembly of claim 13 , further comprising a support tube positionable within the inflatable tube, wherein the support tube comprises pores defined therein, wherein the pores are configured to fluidically couple a source of pressure to the inflatable tube.