Heat Exchanger Assemblies and Methods

Heat exchanger assemblies are provided that can include: a heat exchanger housing; at least one primary conduit operably coupled to the heat exchanger housing and configured to convey a primary heat exchange fluid; at least one secondary conduit operably coupled to the heat exchanger housing and configured to convey a secondary heat exchange fluid; at least one thermal interface between the primary and secondary fluids; and at least one sensor operably engaged with the thermal interface. Heat exchanger assemblies including molten salt, liquid metal, or water/steam as part of the heat exchange fluids of the heat exchanger assembly are provided. The heat exchanger assemblies can include: at least one thermal interface between primary and secondary heat exchange fluids of the heat exchanger assembly; and a sensor operably engaged with the at least one interface. The sensor must be installed in conjunction with the heat exchanger fabrication process as an embedded sensor. Methods for determining the structural integrity of a thermal interface within a heat exchanger assembly using the sensor are provided. The methods can include, while at least one or both of the primary or secondary conduits contain heat exchange fluid, reading structural integrity information of the thermal interface between the heat exchange fluids using one or more sensors engaged with the thermal interface.