CuproBraze - Repositorio
Contents
1. gt Table 3 The composition of OKC600 brazing powder The alloy has been patented US patent 5 378 294 by Outokumpu but can be freely used for automotive and heavy duty industrial heat exchanger applications Melting temperature is 600 C and melting range 10 C Quantity d dE Sa Copper Cu Balance 3 2 Powder m ske The brazing filler metal is produced by gas atomizing to spherical fine powder The maximum particle size is 90 um 3 5 mils and average particle size is 15 to 30 um 0 6to 1 2 mils depending on source Follow carefully the storing instructions shown on the package and or data sheet In case the powder oxidizes during storing it can Pe reconditioned by powder manufacturers During year 2000 production licenses will be granted to qualified powder producers in America Europe and Asia The competition will bring down the purchase cost of th powder gradually to a very reasonable tevel 0000000000000000000000000000000000000000000000000000000 3 3 Pastes by Degussa H ls AG TRA Contact Degussa H ls AG Precious Metals Division Rodenbacher Chaussee 4 Business Unit Technical Materials P O Box 1345 D 63403 Hanau Wolfgang Mr Helmut Kiosterbecker Pee Md NM Manager of Customer Service Brazing Telephone 49 6181 59 2623 E sa duos a Technology SES A Telefax 49 6181 59 4893 E mail helmut Kotar de BrazeSkin SCu200 Water based paste2. Application Tube coating Two components paste to be mixed by the customer powder 80 binder 20 on the spot The powder has a tendency to oxidize when mixed with the binder and can therefore only be stored for a very limited period of time Packaging in 25 kg drums Po and 10 kg drums binder Viscosity adjustable to application technique Specific density 3 4 glem Drying temperature 100 120 C BrazeSkin DCu200 Solvent based brazing paste Application Tube to header joint The paste has to be mixed with alcohol by the customer Packaging in 25 kg drums HIDE TU E T AA MIS U BrazeSkin RCu200 Thermoplastic brazing paste Old Re pose Application Fin tip coating Applied by roller coating method Packaging in 5 kg plastic tubes Metal content 85 to 95 Viscosity 5 to 10 Pas depending on temperature EW Specific density 4 to 5 5 g cm 2 x E Softening temperature 45 to 65 C Ar Melting temperature gt 70 C U Solvent emission 0 Vol Shelf life 6 months MSDS s Materials Safety Data Sheets of all products are available at the producer 3 4 Pastes by OMG Americas Contacts OMG Americas 2601 Weck Drive Gary Cowan P O Box 12166 Manager International Sales Research Triangle Park NC 27709 2166 USA Tel 1 919 544 8090 Fax 1 919 544 7996 Director E mail gary cowanQomgi com or anil nadkarni emgi com Anil V Nadkarni Thermoplastic TP100 Series Applications Tube co
3. After spraying the coating is dried using hot air The drying is complete when the coating i is free from water or solvent It is important that the coating is not overheated When the coating becomes brownish it has been destroyed The coating thickness is measured by weighing The recommended quantity is typically 150 to 200 g m of tube surface area A thicker coating can compensate for wider tolerances of the fins Machine deliveries by Sch ler GmbH Frankfurter Strasse 4 6 D 23689 Pansdorf Germany Tel 49 4504 6010 Fax 49 4504 601 133 e mail sale senoeler de Website www schoeler de Contact Jan Sch ler thes ee 4 2 Fin tip coating The principle of the fin tip coating application is that the fin tips are brought in contact with warm thermoplastic paste with a certain thickness on roll surfaces After passing the gap between two rolls and cooling down the fin tips have a coating of solid thermoplastic paste One type of application method is shown in figure 2 The warm thermoplastic paste is applied on warm rotating rolls and the paste layer thickness is adjusted with scrapers The roll speed and the pressure on the scrapers will adjust the thickness of the paste layer It is important that both the rolls and the paste are at the same temperature in the range for the lowest viscosity of the paste e g 100 to 130 C 212 to 226 F ES For small prototypes the fin tip coating can be arranged ia using
4. Esta tecnolog a disminuye costos de Producci n En Chile se importan USD 3 000 000 al afio en Radiadores principalmente de Aluminio Pl stico lo que implica un gran potencial de sustituci n de importaciones y luego de exportaci n Tecnolog a Cuprobraze se desarrollo pensando en el Medio Ambiente Es una aleaci n autofundente por lo que no utiliza fundente plomo ni otro mineral contaminante La Aleaci n de Cobre no posee Cadmio El Ciclo completo de los Radiadores Cuprobraze es significativamente m s ecol gico que el de Aluminio desde la extracci n de la materia prima hasta el reciclado de los radiadores fuera de uso El objetivo de esta tecnologia es recuperar y sustituir el uso del aluminio en la fabricaci n de Radiadores Se busca el estudio e implementaci n de un proceso piloto que permita la adaptaci n de la tecnologia para fabricar Radiadores CUPROBRAZE a una escala adaptada a la realidad nacional Evaluar e investigar el uso de esta tecnologia en la fabricaci n de intercambiadores de calor industriales e Intercoolers Principales Resultados del Proyecto y Conclusiones Se produce la Transferencia Tecnol gica de Outokumpu a Radiadores Gallardo Laporte S A La tecnologia Cuprobraze presenta un gran potencial y cuenta con el respaldo de Outokumpu y otros productores mundiales de Cobre Ademas de ICA El objetivo final es recuperar terreno perdido con el Aluminio La tecnologia Cuprobraze esta en su etap
5. market gt ing an industrial boiler gas turbine type power generator and Smoke extraction equipment In addition to heat mesni for railway cars NAJICO has supplied many heat ex Pepija on pave 2 e 2 continued from page I A New Generation a changers for installation in large power plants It fabricates heat exchangers for 9 construction machinery cranes for use on board ships and hydraulic units for incor porationin various industrial machines e The company has to date used the solder ing process in the manufacture of heat ex e changers for motors used generally in in dustrial equipment It believes that a high degree of efficiency low production costs O simplified production methods and a reduc ed impact on the working and general en Q vironment will be achieved by making use e of the CuproBraze process Mr Hiromu Nakamura President of gt gt NAJICO who made the decision to adopt the CuproBraze technology says We have e studied the performance and durability of 0 heat exchangers and the methods of joint e ingcopper materials for many years Since 1997 when we first learned of the Cupro Braze technology we have investigated its practicality It became clear to us that by replacing soldered copper heat exchangers with a stacked type radiator fabricated by means of the CuproBraze process we would be able to manufacture radiators and At pr
6. billion to 3 bil x S2 d Mr Gert Lundmark of odt kiim Copper Strip in charge of the CuproBraze project in Asia says We have been engaged in an information campaign with respect to CuproBraze since the spring Of this year We consider that the decisiori of Nakamura Jico to adopt this technology will demon strate the strength and durability of heat exchangers on which it is based its cost effect superiority and its environmental friendliness We interid to assemble as much data as possible from this project to encourage wider acceptance of the technol ogy for the manufactur of automobile radiators ex NEM We very much appreciate the positive atti tude of Nakamura Jico in adopting the tech nology he concluded re lion yen is T sales of rantversal joints and heat exchangers and 8 billion yen from sales of railway car components The total annual production of heat exchangers is ap proximately 6000 units of various capac ities The Nakamura company its business activities internationally through four associate companies overseas zr LIUC gt ae SENE if a ES contacts at one time at one place He attended the seminar together with two other representatives of Outokumpu John Hipchen and Yoram Shabtay ofthe Chi cago office imo i On the first day John Hipchen presented a contaned on nave 3 Ax lt S
7. copper phosphorous and nickel phosphorous compounds are formed during brazing Due to decreased wetting ot this compounds compared with brass and copper strong fluxes have to be used Many of the fluxes used for brazing of stainless steel can satisfactorily be used for repairing These fluxes give corrosive residues and the careful rinsing of the joints has to be done dui Dif eas t 0000000000000000000000000000000000000000000000000000000 E gt 8 2 Re brazing Another way of repairing is to apply additional brazing slurry and re braze 5 95 M Apply slurry at the failure site and dry Re braze the core with the same brazing GBA as usually During re brazing the fins will be slightly softer and due to increased alloying ofthe fins the heat performance may be slightly decreased Re braze with the RA side up to keep tube to header joint sealed or to fix tube to header Pak Mh et How to start Outokumpu has built a Brazing Center in Vasteras Sweden to help customers in building prototypes and evaluating the technology E de ate te Contact Outokumpu Copper Strip AB Markku Ainali General Manager Technical Development SE 72188 Vasteras Sweden Tel 46 21 198223 direct line 46 21 198000 Fax 46 21 198041 E mail markku ainali Qoutokumpu com u MM UN Information updating E BIBLIOTECA GORRO T T NA c ur Websites 5 www copper org International Copper Association s ICA w
8. del proyecto e Evaluar e investigar la aplicaci n de la tecnologia CUPROBRAZE en la fabricaci n de Intercambiadores de Calor e Intercoolers Tipo de Innovaci n Desarrollada Transferencia de Tecnologia Cuprobraze y adaptaci n de sta a escala de producci n y realidad Chilena Nuevo Proceso para la Fabricaci n de Radiadores Automotrices Desarrollo de Prototipos para la Fabricaci n de Enfriadores de Aceite Industriales en Cobre y con Tecnologia Cuprobraze C Metodologia y Plan de Trabajo Recopilaci n de Antecedentes y Literatura entregada por Outokumpu Visita a Outokumpu Suecia Ingeniero Rafael Gallardo para transferencia tecnol gica e Fabricaci n de M quinas y procesos prototipos C Metodologia y Plan de Trabajo Implementaci n de Procesos Piloto Pruebas y Ensayo Visita a Outokumpu Suecia Rodrigo Gallardo Jefe del Proyecto y Gerente General de Radiadores Gallardo Laporte S A C Metodolog a y Plan de Trabajo Fabricaci n Prototipo Panal Automotriz Fabricaci n Prototipo Enfriador de Aceite Pruebas a 100 psi sostenidos de Presi n Pruebas y Evaluaci n de Prototipos D Resultados Obtenidos Transferencia Tecnol gica Visita Ingeniero Rafael Gallardo Laporte a Centro T cnico y Planta Piloto Cuprobraze en Outokumpu Suecia Septiembre A o 2000 se in CONAN lt lt W S By ndunyono 0000000000000000000000000000000000000000000
9. joint Those include the purely mechanical effect of restrain to plastic flow of the filler metal e offered by the greater strength of the base metal the possibility of slag entrapment the possibility of void forming and the relationship between the joint gap width and capillary force which accounts for filler metal distribution UAE TUM T Y jg In both soldering and brazing interactions between the filler metal and the base metal take E place Due to the higher temperature the interactions are sometimes heavier in brazing The interactions are time and temperature dependent and to minimize the interactions the brazing temperature should be as low as possible and the time at brazing temperature as short as possible 2 Copper alloys A KTORE The brazing temperature is higher than the softening temperatures for the coneitional Zrak copper alloys used in soft soldered radiators Therefore special copper alloys have been developed for brazed radiators and it is necessary to use those alloys R ROSJ The tube material is a CuZn15 brass with about 1 additional alloying elements to prevent softening of the material during the brazing operation Typical material properties are shown in table 1 and 2 Bi Y The copper fin alloy is of dispersion hardening type which means that precipitates prevent the material from softening The high conductivity is reached during the brazing operation Table 1 Mech
10. layer than a solid metal The geometry of the tubes and fins and E tube SP in the header have to be adjusted accordingly teta Vo 5 1 Tubes High frequency HF welded tubes are easiest to use for CuproBraze amp radiators because their shape is well controlled and they form a defined gap between the tube and the lt header The HF tube mill is relatively expensive and the wall gauge is limited to min 0 12 mm 0 005 HF tubes are however sold commercially Main suppliers of CuproBraze tubes are are Arzon Ltd in Canada Thermal Components TCI and Hot 8 Coolin the gt USA see contact information below Arzon Ltd Thermal Components Hot amp Cool Tubes Mr Jeff Carrubba Mr Webb Cowden Mr Dick Thrasher 85 Burford Road 2760 Gunther Park Drive 83 Woodrock Road Hamilton Ontario West Weymouth Canada L8E 308 P O Box 3253 Massachusetts 02189 Tel 1 905 561 2424 Montgomery Alabama 36109 USA l Fax 1 905 561 2362 USA Tel 1 781 335 5164 Internet Tel 1 334 277 1810 Fax 1 781 331 9276 www arzonlimited com Fax 1 334 271 4210 gra das E mail E mail info arzonlimited com wcowden Qthermalgroup com Lock seam tubes are used in a majority of soft soldered radiators They are manufactured in lower cost machines of thinner brass strips thicknesses down to 0 085 mm 0 003 Development of lock seam tubes for CuproBraze is underway Laser welding of thin gauge flat oval tubes is a new develop
11. melting when the temperature exceeds 600 C EA 274 65 E The graph in Fig 5 shows the allowable temperatures and times for a successful brazing process que m SUSE A id obetnie E gt gt U Brazo Window 670 Rm 665 Eis 660 Zi 655 ig mm 650 a 645 la 635 ego 620 OD TRE aaeh H vh ER E U NS jo dar sa Ma A ism ARE a X is R E i Max Temp C Time above 600 C e pp 44 lt gt lt lt lt lt lt lt lt PMS ss ms at Fig 5 Brazing operating window for succesful thermal performance result o CAD The heat exchanger will gradually lose thermal performance if the time above 600 C is too long or the temperature is too high On the other hand the part will not braze if the time above 600 C is too short or the temperature is too low We must pay careful attention to the temperature profile because the effects of a cycle that is too hot or too long can not be seen with the naked eye ttn as 6 2 Furnace Selection To select a suitable furnace we must first consider the following Production volume Part size Floor space available Capital expense Operating cost 6 2 1 Suitable Furnaces With the specifications outlined above there are three types of furnaces suitable for no CuproBraze process A batch furnace uses the same door to load and unload the part These furnaces can on
12. ns a 2 Fully automatic machines installed at the Brazing Center Fully automatic machines for the fabrication of CuproBraze radi ators are being installed and are undergoing testing at the Brazing Center at V ster s Sweden We have requests from all over the world for the opportunity to study the automated process says Kurt Svanberg newly ap pointed Manager of both the Vas ter s Brazing Center and the Technical Center at Finsp ng A tube coating machine and a fin tip coat ing machine are now in place and will soon be followed by a header slurry machine Kurt Svanberg says The tube coating machine has been built in collaboration withthe German company Sch ler GmbH Ithasa high production capacity is envi ronment friendly and is the first of its kind for use with CuproBrazing The header slurry machine is also a result of cooper ation with Sch ler GmbH and is unique for this process The fin tip coating ma chine has been designed and built by Outo kumpu Operations previously performed manually are now completely automatic continued from page 2 CuproBraze Seminar paper with the title Materials and Proces ses He was followed by Anil Nadkarni OMG who spoke about Binders Filler Metal Paste Jan Sch ler of Sch ler GmbH chose three different concepts of Paste Applications Machinery as his sub ject and Jeff Boswell Semi
13. of the furnace Since the door is closed during the cycle the consumption is less The nitrogen consumption must be five furnace volume changes per hour The formula to calculate the nitrogen consumption of a batch furnace is as follows Winternat X Hinterna X Linternal X 5m h Where L Length ER Semi continuos furnaces are a combination of continuos and batch furnaces Both calculations must be combined We must determine the time the doors are opani and closed over a period of one hour of operation 6 2 4 Effluent Effluent is generated when the binder is volatized 450 C This effluent must be dealt E with so as not to contaminate the atmosphere in the furnace e cece ares In the furnace the constant flow of nitrogen will expel the effluent from the PIRE atmosphere Z SL When these fumes exit the furnace the gases must either be burnt or diluted with ambient atmosphere to the local specification The law changes from country to country ana state to state so one must check with the local authorities before designing a furnace i 7 Post braze Treatment 7 1 Cleaning after brazing Normally no cleaning is needed after brazing operation 7 2 Coatings mao The corrosion resistance of a CuproBraze amp radiators is better than that of soldered Se DE radiators The nobility of the brazing alloy is of the same level as copper and dinos CuproBraze radiators are mechanically strong and facilitate do
14. tecnologia para la fabricaci n de Radiadores en Cuprobraze e Se tiene acceso a uso del centro T cnico de Outokumpu Esto implica trasferencia tecnol gica permanente asistencia t cnica acceso a sus laboratorios uso de maquinaria para construcci n de prototipos y uso de tunel de viento para evaluaci n de productos D Impactos del Proyecto e Se desarrollo prototipo de Enfriador de Aceite para aplicaciones industriales sometidas a presiones de hasta 100 psi e Estos enfriadores son fabricados en el mundo en Aluminio brazado o Nocolok presentando excelentes resultados en t rminos de transferencia de calor pero su durabilidad en ambientes agresivos es muy baja por la alta corrosi n que sufren Lo anterior hace que su performance en aplicaciones mineras en Chile sea deficiente 03809 YO3LONAIg AR ren D Impactos del Proyecto El potencial de sustituci n de importaci n de este tipo de productos es de sumo interes Actualmente se fabrican estos enfriadores en Chile con Tubos o Ca er as de Cobre y L minas de Aluminio Su uni n es por proceso de expandido En algunos casos se usan l minas de Cobre El performance de estos equipos es bajo y no se alcanzan las eficiencias de los equipos de aluminio en el espacio solicitado D Impactos del Proyecto El acceso a esta tecnolog a permite evaluar la posibilidad de incorporarla a escala productiva nacional ya que la tecnolog a equ
15. the Bronze Age archae ologists now speak of an intermediate Cop per Age The remarkable find in 1991 in the European Alps of the body of a man now referred to as Otzi preserved for 5300 years in the ice was made even more interesting by the discovery of a service able copper axe as part of his equipment history of copper in association with the use of the modern CuproBraze technology This had survived until our time because of the resistance of copper to corrosion The most important property of copper to day is its excellent conductivity of heat and in particular electricity Silver is the only metal superior to copper in this re spect gold having almost 80 and alumin ium 60 of the conductivity of copper This explains why copper remains at the technical forefront in our electrified world of computers and information transfer tech nology Copper remains in great demand for use in cables and computer components but it has many other uses Copper is a relatively soft metal and is readily formable It can be alloyed with other metals without losing its workabil ity The superior machining properties of certain copper alloys and the ease with which they can be joined give modern users Activities i in Asia ve coorte am ta term The entire automotive industry in Asia continues to show great in terest in the CuproBraze technol ogy and is acting accordingly says Gert Lundmark Marketin
16. the process for both CAC s and AC heat exchang To meet this demand we now have an extensive development programme under way to adapt the process and to present product concepts in these areas lt T m 0000 X n A 2 A 0200000000006 Prototype CuproBraze radiators evaluated at Technical Center E ai Ng Kurt Svanberg Manager of the Technical Center at Finsp ng Sweden standing by the wind tunnel designed and built by the company The wind tunnel is an important factor in our cooperation with customers By means of an extremely effective com puter program for calculations incorporated in the wind tunnel we can effectively develop test and evaluate proto types for our customers says Kurt Svanberg Manager of Qutokumpu Copper Strip s Technical Center at Finsp ng Sweden Interest is now focussed on CuproBraze and the projectsin Outokumpu Copper Strip is the only manufacturer of strip with its own wind tunnel and this has been design ed developed and built by the com pany itself The development of a pro tolype for a customer takes between 5 and 7 weeks continues Kurt Svan berg It can be for example a prototype with the same performance as the cus tomer s radiator but lighter being of Cupr Braze construction Investigation of details If the customer has queries and re quirements with respect to the proto type we can study these in detail A
17. 000000000000 M quina ubera M quina que fabrica los tubos de Radiador El Radiador Cuprobraze funciona con tubos sin costura Se est n haciendo pruebas con tubos emballetados para f bricas de menor escala de producci n Outokumpu Suecia Lab Proyecto Cuprobraze N Secado de Tubos con Pasta Se empasta tubo a tubo en forma manual y luego se ponen los tubos en esta bandeja transportadora para su secado 2 aa RS 2 lt gt Outokumpu Suecia Laboratorio Proyecto Cuprobraze Secado de Tubos con Pasta Proceso Experimental de Secado de Tubos con Pasta de Brazado Outokumpu Suecia Laboratorio Proyecto Cuprobraze Maquina de Rodillo Maquina de Rodillo para la fabricacion de aletas o rizos de Radiadores Outokumpu Suecia Laboratorio Proyecto Cuprobraze Rodillos para Mag Aletas M ltiples set de Rodillos para fabricar distintos tipos de Radiadores Outokumpu Suecia Laboratorio Proyecto Cuprobraze 9000000000000000000000000000000000000000000000000000000 Aplicaci n de Pasta a Rizo Experimentando formas de aplicar pasta de brazado a Rizo oe aprecia en la foto forma de aplicar manual y distinta a la del ARE EXE Manual T cnico Outokumpu Suecia Cuprobraze Feb Laboratorio Proyecto 2000 Cuprobraze Sacar exceso de Pasta Rizos despues de ii poner pasta Outokumpu Suecia Pruebas de Aplicaci n de Pasta Laboratorio Proyec
18. 00000000000000000000000000000000000 000000000 00 000000000 T CODIGO TITULO EMPRESA GESTORA FECHA 629 23 R 129 2001 13 23 2 RA29 2004 Cu lye FONTEC CORFO 199 2024 FABRICACI N DE RADIADORES CON NUEVA TECNOLOG A CUPROBRAZE RADIADORES GALLARDO LAPAPORTE S A Octubre 2001 bege oo PRESENTACI N En el ltimo decenio se constata que el pa s ha sabido enfrentar con xito el desafio impuesto por la pol tica de apertura en los mercados internacionales alcanzando un crecimiento y desarrollo econ mico sustentable con un sector empresarial din mico innovador v capaz de adaptarse r pidamente a las sefia es del mercado Sin embargo nuestra estrategia de desarrollo fundada en el mayor esfuerzo exportador y en un esquema que principalmente hace uso de las ventajas comparativas que dan los recursos naturales y la abundancia relativa de la mano de obra tender a agotarse r pidamente como consecuencia del propio progreso nacional Por consiguiente resulta determinante afrontar una segunda fase exportadora que debe estar caracterizada por la incorporaci n de un mayor valor agregado de inteligencia conocimientos y tecnologias a nuestros productos a fin de hacerlos m s competitivos Para abordar el proceso de modernizaci n y reconversi n de la estructura productiva del pa s reviste vital importancia el papel que cumplen las innovaciones tecnol gicas toda vez que ellas conf
19. C conocidos como Intercooler son utilizados en Camiones y Buses principalmente Outokumpu Centro T cnico Vaasteras Suecia El tubo es armado a partir de dos L en plancha de 0 8 mm de espesor En su inferior se inserta un Rizo para retenci n del Aire ca da de presi n necesaria y mayor rea de transferencia en contacto con el aire Escuadras en Planchas de 1 0 mm de espesor Outokumpu Finspang Suecia La Tecnologia CuproBraze est en una etapa Experimental avanzada y de Introducci n a varios fabricantes del Mundo e Tanto Outokumpu como varios fabricantes est n experimentando y desarrollando prototipos para aplicaciones Industriales como enfriadores de aceite e intercoolers 409 vo3lOngg 0 Outokumpu Finspang Suecia En Radiadores hay dos mercados a OEM y b Aftermarket Inicialmente se quer a el uso de esta tecnolog a en OEM Original equipment manufacture Fabricantes de Automoviles Este mercado es dominado por pocas empresas en el mundo las que no quisieron adoptar inicialmente la tecnologia Cuprobraze Outokumpu Finspang Suecia Al Orientarse al mercado Aftermarket Mercado de Reposici n f bricas como las nuestras pueden entrar en el proyecto En esta etapa los fabricante OEM est n experimentando con la tecnologia y en etapa de desarrollo de futuros modelos para automoviles nuevos Outokumpu Finspang Suecia e La tecnolog a fue
20. Je ec seJopeipey M quina Aletadora M quina Estampadora de Aletas para Radiador Industrial 100 Matriz Colectores Industriales Matriz para estampar colectores industriales 80 estado de avance En planta piloto Outokumpu utilizaban una punzonadora autom tica y programable Radiadores Gallardo Laporte S A Proyecto Cuprobraze soqn ep euinbeia 00000000000000000000000000000000000000000000000008000000 d wa c ty E a OR 2 WI gt manu soqn ep euinbejn sogn ep euinbei Tubos emballetados Tubos emballetados Transferencia Tecnol gica e Visita Rodrigo Gallardo Diaz a Centro Tecnico y Planta Piloto Cuprobraze en Outokumpu Suecia Vaasteras Finspong e Junio A o 2001 t t 2199NS sSeJ9 seeA 091UD9 0 99 NAWN OJNO Opejoe equJe 9 uo opezeig op ejsed op uoioeoi de A sopejo equue soqn eJed ejeqn eI28ng SeJojseeA 091U99 O1 U89 ndwnyojno 00000000000000000000000000000000000000000000000000000090 BIN SOD uis soqn eJed eJeqn e199NS seJojseeA ODIUD8 OJU99 ndwnyojno Outokumpu Centro T cnico Vaasteras Suecia Panal Prototipo para fabricaci n de Charge Air Coolers enfriadores de Aire de Los Turbos en Cobre con Tecnologia Cuprobraze Actualmente el panal es fabricado en Aluminio con tecnologia Nocolok y Aluminio Brazado y Ambos Estanques en Alumino Fundido Los CA
21. POST BRAZE TREATMENT TT ET E E TETI EI DRESS SETITI TETE SETITI SET ii Te q ossevsac nIeopeV o eq uoon x 7 1 CLEANING AFTER BRAZING 46 7 2 COATINGS B REPAIRING od retento e td oeste cnt NR S 1 SOFT SOLDERING roads eretas uisus Lot aon ntc O dd U 8 2 RE BRAZINO oo obada ani R aii ja SIC Td MED ja a Ca em RUNI ada EI byr 1 General The CuproBraze process is a brazing process specifically developed for the manufacturing of automotive and heavy duty industrial heat exchangers By using high strength and high conductivity copper and copper alloys it is possible to manufacture light strong efficient and compact heat exchangers at a low cost with this environmentally friendly process 1 1 Brazing theory Soldering and brazing involve the same bonding mechanism Soldering is detineda as s using filler metals with melting temperatures below 450 C 840 F Brazing is defi ined by the use of filler metals that have melting temperatures higher than the above temperature limit In both soldering and brazing the bonding mechanism is a reaction between the brazing alloy and the parent metal Usually it results in alloying to form a metallic bond at the interface The filler metal flows into the joint gap by capillary force and forms a bond Joint clearance and geometry have several effects on the mechanical performance of the finished
22. a pacities and the equipment for ap plying brazing paste to copper brass radiator tubes and fins Why this great interest in Cupro Braze technology Because the market has discovered it to be continued on page 4 per and brass materials in heat Aa A A AA O E o ici E AU Mi ET CTS me A A x tor TUE z mt Staffan Anger President of Outokumpu Copper Strip AB of Sweden has announced that Nakamura Jico Co Ltd NAJICO a large Ja panese manufacturer of industrial heat exchangers has decided to adopt the Outokumpu CuproBraze technology for manufacturing cop per brass heat exchangers and will begin full scale production of stack ed type heat exchangers using the CuproBraze technology during I autumn Tt The President of NAJICO which has its head office at Tsukiji Chuo Ku Tokyo is Hiromu Nakamura Outokumpu Copper Strip has its Japanese branch office at Nihonbashi Chuo ku Tokyo NAJICO will now be the first Asiatic com pany to adopt the CuproBraze process for use on a commercial basis NAJICO was appointed an authorised sup plier to the then Japanese Ministry of Rail ways in 1934 and began supplying parts for buses operated by the Ministry a ye Me ae The company has since or uk in the design manufacture and sale of railway car components and heat exchangers uni versal joints for diesel coaches and various industrial machines It is currently
23. a de introducci n y varios fabricantes en el mundo est n en su etapa experimental y estudiando la implementaci n en otras aplicaciones a los radiadores de agua como Intercooler y enfriadores de Aceite Se fabrica maquinaria para proceso y construcci n de prototipo Se fabrica prototipo de Panal Automotriz con tecnologia Cuprobraze con resultado positivo Se investiga en productos como enfriadores de aceite e intercoolers Radiadores Gallardo Laporte S A fabrica un prototipo de Enfriador de Aceite Aire para ser desarrollado con tecnologia Cuprobraze Se fabricar un prototipo que se ha estado desarrollando para fabricar Charge Air Cooler en Cobre o intercooler el que ser evaluado por Outokumpu Se establece relaci n de trabajo de largo plazo con Outokumpu para el desarrollo de esta tecnologia y se tiene acceso a uso del centro T cnico de Outokumpu Esto implica trasferencia tecnol gica permanente asistencia t cnica acceso a sus laboratorios uso de maquinaria para construcci n de prototipos y uso de tunel de viento para evaluaci n de productos B Exposici n del Problema e Antecedentes T cnicos del Proyecto Objetivos T cnicos y Resultados Perseguidos ipo de Innovaci n Desarrollada Antecedentes T cnicos del Proyecto Tecnologia desarrollada por Outokumpu e ICA Asoc Internacional de Cobre para competir con los Radiadores Aluminio Pl stico que est n reemplazando el uso de Cu en esta Aplicac
24. a hot plain metal sheet on which the paste is applied Hot rolls 95 to 100 C 205 to 215 F Scrapers Scrapers Cold air US g Cold air blowers blowers LT lt I aa er Warm brazing paste Fig 2 Principle of the fin tip coating method NOTE Above 130 C 226 F the brazing properties of the paste will be destroyed The amount of paste is measured by weighing The recommended amount of paste is 0 3 to 0 5 mg mm fin tip width 2 7 10 to 4 5 10 oz in The smallest Is for fins with best tolerances Machine deliveries by Sch ler GmbH Germany see 4 1 for contact information 4 3 Tube to header joint The most critical braze joint of the radiator is the tube header joint as it has to be totally leak free It is thus imperative that enough braze material is in place when 128 ee place A dedicated slurry is used for tube header joints The slurry is a mix of powder Lindos and solvent It can be applied by pouring or spraying Both methods are very well suited for automation and if the header design is right it also 5 gives low braze material consumption oy 5 Components and assembling A brazing operation requires better defined joints than soft soldering Generally closer tolerances and well defined joint gaps result in better and stronger joints Another aspect to take into account is that the brazing alloy is in powder form and will build up a thicker
25. anical properties of Outokumpu s copper and brass materials for o CuproBrazeQ PORE SM 0502 SM 2385 Medi i Bef brazing After brazing Bef brazing After brazinga Savoury Bal E Conductivity 96IACS 60 94 35 30 ksi 49 38 49 39 SR A Ksi 58 48 61 58 50 270 0 f 4 For header side support CuZn36Ni3 type j SN Roe Properties vt Table 2 Physical properties of Outokumpu s fin copper and tube brass for CuproBraze 2i SM 0502 Ib in 0 321 Melting Temperature C 1083 F 1981 Specific Heat kJ kg C 0 385 BTU Ib F 0 092 E s Thermal Expansion C 17 7410 1991055 oe 20 300 C 68 572 F CF 9 8 10 10 6107 Mod of Elasticity N mm 118 000 ksi 17 093 3 Brazing powder 3 1 Basic alloy 3 NR T Figure 1 shows the principal braze alloy families and the corresponding melting ranges Mi Observe Cadmium containing metal filler should not be used due to toxicity ar gt ra 1 S P lt 4 y 4 000 m 800 z b s E i u Brazing 5 AG T Sem Soldering se 200 E SnPb OK600 AgCuZnCd CuZn BARZE i ZNACUTI CuNiSnP CuPAg x es Figure 1 Soldering and brazing alloy families and their melting ranges The CuNiSnP family group includes the brazing filler metal developed for brazing of radiators This filler metal is called OKC 600 with compositions shown in Table 9
26. asing strongly and mon than 20 countries have Applied for en try to the Tour in 1999 Outokumpu Copper Strip s decision to sponsor the world orientecrin championship together with the Erics son concern is based in part on thc company s interest in the Chinese market Qro de NE NS dir Ste NS E continued from page I y From the president tors to the advantage ot CuproBra e ir these fields Outokumpu Copper Strip hasan inter national group of engineers who are your disposal to provi e assistance ir projects to develop Your products Staffan Anger OUTOKUMPU COPPER STRIP PRODUCTS Sweden A SE 721 88 Vasteras Sweden Tel Int 46 21198000 Fax int 46 21198041 Tix AMEN ocestit S ns a Stalan Anger interest in the CuproBraze process During recent months several fur ther companies have made the de cision to invest in the CuproBraze process CuproBraze technology is now applied in production facil ities in the US in addition to Eu rope and the Far East Other com panies in different parts of the world are in the final stages of their evaluation of the process which we confidently expect will convince them of the superiority of the Cup roBraze process for jointing cop transfer products Equipment required for the use of the CuproBraze process is now available from different suppliers who offer furnaces of different c
27. ating Brazing alloy powder thermoplastic binder Applied by dipping in a molten pool or by hot spraying Solidifies quickly to a hard adherent coating Metal content 85 to 9595 Melting temperature 55 6 130 F Thermoplastic TP200 Series Applications Fin tip coating Brazing alloy powder thermoplastic binder Applied by using fin tip coating machine or by dipping Solidifies quickly to a smooth tough coating Metal content 85 to 95 Melting temperature 75 C 1166 F W Slurry SL100 Series Applications Tube to header or tube coating a Brazing alloy powder solvent binder designed for coating header Applied by slurrying or spraying Metal content 85 to 95 MSDS s Materials Safety Data Sheets of all products are available at the producer 3 5 Others There are also other companies developing pastes One of them very close to commercialisation of their products is Lucas Milhaupt in USA Contact person is AM Shah e mail lucas_milQ4Qearthlink net 4 Paste application For tube fin joints the brazing paste is applied alternatively on the tube or on ne fin tips Normally no precleaning is necessary d b 2 4 1 Tube spraying The paste is applied on the tube surfaces usually by spraying with a spray gun Water based paste is normally used for radiators with corrugated fins and harder solvent based paste for flat fin push tube radiators Suitable spray guns exist in the market
28. concebida pensando para la fabricaci n de Radiadores Pero con el tiempo se ha manifestado un alto inter s de parte de los fabricantes en el usos de esta tecnologia en Intercooler y Enfriadores de Aceite industriales JELISNPU eyeoy ep Joperju3 odiojoJg ZINOLUO NY eued OdI O OJd W S ouode7 OpJe ED seiopelped ZJOLOINY Jeueg OdIJOJOJ A Prototipo Panal Automotriz Pruebas de Adherencia Epiat ae E REG Codi AA SARE KIA EK NE OR RE Rea AM a HER OS ESTES LUSO SDN E OTO REAR ON GA OCZU SER Z AIC N A NAM EAS ASCENSOR ERR ae noL SAS DBK ESSE IE tors CZT RCS Prototipo Enfriador de Aceite Industrial Proceso de Fabricaci n de Panal y Estanques Enfriador de Aceite Embudo Prototipo Enfriador de Aceite Industrial Prototipo enfriador de Aceite Aire Disefiado bajo Normas Ambientales de Emisi n de Ruidos Polvo y Reciclaje del equipo Bomba de Aceite Filtro y Malla Protectora D Resultados Obtenidos y Conclusiones Se produce Transferencia Tecnol gica de Outokumpu a Radiadores Gallardo Laporte S A La tecnologia Cuprobraze presenta un gran potencial y cuenta con el respaldo de Outokumpu y otros productores mundiales de Cobre Ademas de ICA El objetivo final es recuperar terreno perdido con el Aluminio D Resultados Obtenidos y Conclusiones e La tecnologia Cuprobraze esta todavia en etapa experimental e Se est buscando experimentar en otros usos como lo
29. dge of the part Furnace manufacturers Seco Warwick Mr Jeff Boswell Mr Kevin Lipinsky 180 Mercer Street Meadville PA 16335 USA Tel 1814 724 1400 Fax 1 814 724 1407 Sarlin Furnaces AB Mr Anders Jerreg rd Bastborregatan 5 SE 72134 Vasteras Sweden Abbott Furnace Co Mr Thomas Jesberger 1068 Trout Run Road St Marys PA 15857 USA Tel 1 814 781 6355 Fax 1 814 781 7334 Tel 46 21 109800 Fax 4621 123745 6 2 2 Heating Source It is possible to heat all three types of furnaces with one of the following methods Maso Dos A m Electricity Y Natural gas Propane in many countries natural gas and propane is a cheaper source of energy than electricity but requires more maintenance and has a higher initial cost l re gt UAE mA dcm Gas burners are known to provide a better temperature uniformity than e elements Gas burners however require a gas tight barrier between the products of combustion and U the brazing atmosphere Such a barrier can be radiant tubes or a muffle 6 2 3 Nitrogen consumption a For continuos furnaces nitrogen consumption is directly proportional to the opening on either end of the furnace The formula to calculate nitrogen consumption is as follows Wrront X Hiront Wrear X Hrear X 100m h A cha E where W Width and H Height For a batch furnace the nitrogen consumption is based on the volume
30. e left Manager of the Outokumpu Brazing Center at vasterds and Technical Center at Finsp ng and Lars Rojeteg study a sample of coated tube produced by then new tube service EN Development is always difficult but 1 thrive on challenges I will have the po si bility now of directing the available res sources where they are used to the best advantage Mu NP r e Te ER m E Lars Yllner chiller Sch ler ner it was an initiative which I nope will be followed up by other Rome engaged in the radiator field Copper the most modern metal How does the use of copper affect the environment We will present different aspects of this c question in a series of articles in our Newsletter written by Mariann Sundberg Lic Phil who works with environmental questions within the Scandinavian Copper Development Association We begin with a brief ef review of the Copper has always been at the forefront of human innovation activities Both gold and copper occur in solid form in nature and were therefore the earliest discovered metals The largest known single solid cop per find was a huge block weighing 1000 tonnes discovered near Lake Superior in North America It is believed that copper has been used by man for 10 000 years The materials used for tools at the time have given their names to different periods in the history of mankind In addition to the Stone Age and
31. ebsite with general information y www outokumpu com Outokumpu s website with Brazing Manual and Newsletter articles 4 Frequent publications UG Executive Report ICA s paper on CuproBraze g lib Newsletter Outokumpu s paper on automotive heat exchangers VOX Supplier lists are available at ICA and Outokumpu uoder ug opej o Jieseq ojllsoy 90 100 A J9 009 eBseuyd eiunjeJ9jr NAWNY OJNO soxouy 4 0000000000000000000000000000000000000000000000000000000 Cooperation results in shortened lead time Strip Products iosophy Your E partners pm uc H 4 TIME jed partners AD Bu TIME In developing new models of motor vehicles reductions in lead time are of great importance We are convinced that we can contribute to such 4 pluctions by collaboration with the automotive industry and in particular manufacturers of heat exchangers Charge Air Coolers and Condensers New applications of the CuproBraze Process In developing the Cupro Braze Process interest has been mainly concentrated on its use in fabricating auto motive radiators The radi ator is a heat exchanger tra ditionally manufactured of copper and brass and this is a market which the Copper T dustry must defend cine the work of developing the CuproBraze Process we became aware of significant advantages which make it particularly suitable f
32. ed in different ways see Fig 4 a i6 Fig 4 Header manufacturing methods Pierced holes left and middle are recommended Lanced holes right are used for soft soldering and are not recommended for brazing B a o 0000000000000000000000000000000000000000000000000000000 For the CuproBraze process it is recommended to use pierced holes as these joints give a far better fit to the tubes The pierced holes should provide a radial braze gap of 0 05 mm 0 002 between tube and header 5 4 Core building and fixturing As earlier mentioned the brazing powder builds up a thicker layer than a solid metal layer This has to be taken into account when the tube size fin amplitude and tube pitch in the header are determined The tube pitch is made up of nominal fin and tube dimensions As tube dimension widens corrections might be needed like reducing fin height at given tube pitch or vice versa After assembling the cores should have more or less pronounced barrel shape depending on the core size The fixturing has to be adjusted accordingly 6 Brazing Operation The temperature of CuproBraze brazing is much higher than that of the soldering process To prevent oxidation to both the parent and filler materials we need to join the metals in an inert atmosphere In order to select a suitable furnace we must know the temperature time and atmospheric conditions requ
33. esent the company sales department is engaged in marketing railway car com ponents machinery parts and equipment such as boilers and gas turbines The manu facturing department designs fabricates and sells a range of universal joints Nakamura has over a 90 share of the mar ket for heat exchangers for diesel coaches built in Japan for domestic railways and for export and has acquired a very high re f SECO WARWICK USA a world leading builder of furnaces for the automotive radiator in dustry recently convened its first CuproBraze seminar Represen tatives of companies engaged in all phases of the fabrication pru cess were invited oil coolers 20 30 smaller but with the same capacity Radiator performance would be improved by 30 50 and manu facturing cost reduced by 20 30 The lead free process is simpler and is perform ed in a working environment which is sig nificantly improved At present we are studying more effective brazing processes and are in the final stage preparatory to full scale production be ginning this autumn Our heat exchangers are used in associ ation with the motors of railway coaches ships and plant machinery In such situ ations under conditions more severe than those under which motor vehicles normaily operate durability resistance to pressure vibration and corrosion are essential re quirements We have been endeavouring for many years to improve copper heat ex cha
34. ess has a minimum impact on the environment CuproBraze radiators are fully recoverable for reuse Because they retain their prop erties copper and its alloys arethe ma terials most frequently recycled currently as they have been for thousands of years in the past Most copper products on the market today have at least soirie content of recycled copper e BAZ Perhaps your new CuproBraze radiator contains a tiny proporti of metal mon Copper Age mer UM ed Br From the president ae more efficient and less expensive und to have a minimum impact ori the physical environment A technology superior to any of its competitors used f today by the automotive heat ext changer industry ticas m ts Our engineers in Europe Japan and hi US are at your disposal prepared to set up a demonstration pro ram for your evaluation E d Staffan Anger Dol OUTOKUMPU COPPER gta STRIP AB B pum Sweden a Int 46 21198000 Fax Int 46 21198041
35. g Director for Outokumpu Copper Strip in Asia There is an increased interest in sia in the future possibilities apparent in the new technology and this is reflected in the actions of important actors in this field Many representatives of the heat exchanger industry were participants at further in house seminars presented recently in Ja pan by Outokumpu Copper Strip brazing specialists continues Gert Lundmark Seminars have also been held for large Headquarters Outokumpu Copper Strip AB SE 721 88 Vasteras Sweden Tel audiences from the automotive industry and its suppliers in Malaysia Indonesia and The Philippines to provide information about our experiences with the new pro cess Further seminars ure planned Qutokumpu Copper Strip was a prominent exhibitor at the Tokyo Motor Show which even if it focused particularly on the latest in trucks on this occasion drew large crowds from the general public Further seminars and participation in mo tor exhibitions are planned for the present and next years as parts of our programme to continue our presentation of CuproBraze technology a broad spectrum of design possibilities in for example heat transfer equipment such as automotive radiators The latest radiator technology is based on the unique heat conduction of copper and the development of the CuproBraze joint ing process In addition to its general tech nical advantages the CuproBraze proc
36. i n Outokumpu ofrece a Radiadores Gallardo Laporte S A La Transferecia de esta nueva Tecnologia Llamada Cuprobraze Tecnologia Mejora Prestaciones de Servicio y AMBIENTALES en relaci n al los Radiadores de Cu tradicional y los de Al 10 00000000000000000000000000000000000000000000000000 0000 Antecedentes T cnicos del Proyecto El Cobre es la principal actividad econ mica de Chile Esta tecnologia disminuye costos de Producci n Los Radiadores de Cobre son m s resistentes a la corrosi n impacto y vibraciones que los de Al En Chile se importan USD 3 000 000 al afio en Radiadores principalmente de Aluminio Pl stico lo que implica un gran potencial de sustituci n de importaciones y luego de exportaci n Antecedentes T cnicos del Proyecto Tecnologia Cuprobraze se desarrollo pensando en el Medio Ambiente Es una aleaci n autofundente por lo que no utiliza fundente plomo ni otro mineral contaminante La Aleaci n de Cobre no posee Cadmio El Ciclo completo de los Radiadores Cuprobraze es significativamente mas ecol gico que el de Aluminio desde la extracci n de la materia prima hasta el reciclado de los radiadores fuera de uso Objetivos del proyecto Estudio e implementaci n de un proceso piloto que permita la adaptaci n de la tecnologia para fabricar Radiadores CUPROBRAZE a una escala adaptada a la realidad nacional Longa 04409 yog Emo M z e Objetivos
37. ieren sustentaci n real a la competitividad de nuestra oferta exportable Para ello el Gobierno ofrece instrumentos finangieros que promueven e incentivan la innovaci n y el desarrollo tecnol gico de las empresas productoras de bienes y servicios El Fondo Nacional de Desarrollo Tecnol gico y Productivo FONTEC organismo creado por CORFO cuenta con los recursos necesarios para financiar Proyectos de Innovaci n Tecnol gica formulados por las empresas del sector privado nacional para la introducci n o adaptaci n y desarrollo de productos procesos o de equipos Las L neas de financiamiento de este Fondo incluyen adem s el apoyo a la ejecuci n de proyectos de Inversi n en Infraestructura Tecnol gica y de Centros de Transferencia Tecnol gica a objeto que las empresas dispongan de sus propias instalaciones de control de calidad y de investigaci n y desarrollo de nuevos productos o procesos De este modo se tiende a la incorporaci n del concepto Empresa Pa s en la comunidad nacional donde no es s lo una empresa aislada la que compite con productos de calidad sino que es la Marca Pa s la que se hace presente en los mercados internacionales El Proyecto que se presenta constituye un valioso aporte al cumplimiento de los objetivos y metas anteriormente comentados FONTEC CORFO A Resumen Ejecutivo Antecedentes de la Empresa e S ntesis del proyecto de Innovaci n e Principales Resultados del Pr
38. il the important elements of a radiator Headquarters Outokumpu Copper Strip AB o which we are collaborating with customers Nae etc 7 can be adjusted We can perform cal culations to investigate each small part with the help of the calculation pro gram and sce the results via the com puter Tested before delivery Each prototype is tested before it is delivered from the Technical Center The design of each is recorded in a database together with relevant com ments Outokumpu Copper Strip sponsors The Park World Tour Outokumpu Copper Strip has decided to become a sponsor of The Park World Tour the competition for the world s best cross country runnersin thesport of Orien teering The Park World Tour started in Vasa Finland in 1996 initiated by seven orienteering enthusiasts with bases in the Nordic countries They set a high standard for the different events and placed world class orienteering in focus The Park World Tour competi tors are the leading 25 men and 2 women cross country runners and the tour takes these to new countries ana new continents where the sport is breaking ground and growing The Park World Tour 1998 began in March at Beijing China In May the world s best orienteers competed a V ster s Sweden and this event wa followed by races in Finland Italy Austria and the Czech Republic be fore the final at Gothenburg Sweden Interestis incre
39. ired for the process 6 1 General Furnace Parameters Furnaces suitable for the CuproBraze process must have the following characteristics 6 1 1 Atmosphere The primary function of the brazing atmosphere is to prevent oxidation Fama gt today use high purity nitrogen to displace oxygen from inside the furnace The atmosphere of the furnace must have a dew point of less than 40 C and an oxygen content of less than 20 ppm To achieve this very good atmosphere nitrogen gas with a dew point of 65 C and an oxygen content of less than 10 ppm is used successfully today If moisture and oxygen levels are higher than these levels the powder used to form the joints and the base material are oxidized and brazing becomes impossible Therefore the furnace must be gas tight If there are leaks in the shell or muffle oxygen will find a way to contaminate the brazing atmosphere 6 1 2 Temperature and Time u sa es The furnace must be abie to heat the load between 450 C and 650 c with a ramp rate of gt 30 C per minute E DP LM The furnace must be able to cool the load at a maximum of 150 C per minute e Ea No heat should be applied if the atmospheric conditions are not met The pare should not i leave the inert atmosphere if the part temperature is above 150 C Part temperature uniformity must be within 7 C Furnace must be able to operate at a temperature of 700 C The braze filler metal starts
40. ivalente en aluminio es de inversiones de aproximadamente us 8 000 000 y estimamos que la tecnolog a cuprobraze se podr a implementar con una inversi n de us 300 000 0000000000000000000000000000000000000000000000000000000 D Impactos del Proyecto La Tecnologia Cuprobraze es amistosa con el medio ambiente por lo que un producto fabricado con esta tecnologia puede ser exportado a cualquier pa s del mundo F Anexos e Informe Financiero CuproBraze Manual T cnico e Outokumpu Literatura Charge Air Cooler y Enfriador de Aceite Desarrollado en Jap n O9IU99 enuen S ZEJgOJdNO e soxsuv 4 A IA 2 outokumpu February 2000 Ve A ana CuproBraze vas Maira a mr i e w S NS o px 1 Gu mo 0000000000000000000000000000000000000000000000000000000 f Contents T GENERAL a ae nte cono dene S 1 1 BRAZING THEORY lieto alte tons vet se C c t poe itn ics E 2 COPPER ALLOYS iiem E 3 BRAZIN G POWDER ana oO do i T mid 3 1 BASIC ALLO ooi odar tute EEE EE i me POWDER Pm o ep T 3 3 PASTES BY DEGUSSA MULSAG 1 si oto denm eani o lota beta AAAA e Eleal ej sd no ard RER esta nud e BrazeSkin SCu200 Water based paste emen A u BrazeSkin DCu200 Solvent based brazing paste ssssssssssseeeeeeemenn asia g do DA BrazeSkin RCu200 Thermo
41. ly produce one batch at a time A load is purged then moved into the brazing chamber After brazing it is moved back into the purge chamber where it is cooled A semi continuous furnace uses an entry and an exit door Parts are indexed from the loading area to the purge chamber Here the part is purged with nitrogen and then moved into the next chamber The furnace will simultaneously move the purged part to the braze chamber and a new part into the purge chamber It is possible to have a part in each zone of the furnace This is for large parts or intermediate volume production In a continuous furnace a conveyor continuously moves parts through a furnace where they are continuously purged and brazed and then cooled This type of iS i nan volume production IUE r All the furnaces mentioned above must have a heating and cooling section It is not acceptable to load a part into a cold furnace and heat the load and the furnace together It is not possible to achieve the very fast heating rate required with such a furnace Batch furnaces and semi continuous furnaces are suitable for any part size but are ar as regards to production volume A continuous furnace is not recommended for parts longer than 1000 mm When the front of the part enters the heating zone it will immediately begin to conduct heat to the rear of the part This means that the trailing l section of the part will be at temperature for much longer than the leading e
42. ment that combines the well defined shape of a HF welded tube and the ability to use thin material lt 0 1 mm gt 0 004 Laser welding machines for radiator tubes can be purchased from Sch ler GmbH in Germany see 4 1 for contact info For CuproBraze amp process it is recommended to specify tubes with higher crown than ter soft soldering It has been found that it gives a more consistent bond between tube and fin The crown C should be 0 2 to 0 4 mm 0 008 to 0 016 for tube widths of 12 to 25 mm 0 47 to 1 0 i 2 O Fig 3 CuproBraze process needs tubes with higher crown c than soldering process 5 2 Fin The main dimension that influences this process is the fin amplitude The more consistent the better the brazing result Thinner layers of braze material can be applied whichis good both from technical and economic point of view In tube coating method the variation from fin tip to fin tip of less than 0 050 mm 0 002 9 is recommended If the brazing alloy is applied by fin tip coating it is also important that each fin tip is straight and has consistent fin amplitude If not there is a risk that the fin will be deformed and the braze material will be applied in an uneven layer Also here the variation should be kept within 0 050 mm 0 002 9 5 3 Header OPS The major design feature that influences the brazing is the formation of the holes inthe header These holes can be designed and manufactur
43. nar Director and Kevin Lipinski of SECO WARWICK con cluded the programme of addresses with CuproBraze Furnace Systems and The Titusville Facility respectively The demonstration programme was pre sented at the SECO WARWICK Technical Center in Titusville It consisted of a dem onstration of the brazing of copper heat exchangers utilising the CuproBraze pro cess in the new batch furnace which the company has developed More than 30 visi tors from all parts of the world questioned their hosts about the process and the fur nace during the demonstration and the pa nel debate which followed The creron oka conprehersive nr t W o coating machine in the background ar the Brazing Center The price level we will now be able to hold for the product because of its automation will ensure our competitive position in our market As manager of the Technical Center at Fin sp ng Kurt Svanberg has long and wide experience of development and customer The panel at the CuproBraze Seminar at SECO WARWICK included from left Outokumpu Copper Strip Sweden Yoram Shabtay Outokumpu Chicago Jan GmbH and Anil Nadkarni OMG Seminar Director Jeff Boswell absent from pe photo was also a panel member i of CuproBraze was made possible by in viting experts from the entire manufac process l believe that this was very 11 sd v s lt Te Kurt Svanberg at th
44. ngers to ensure these characteristics of strength and durability The most critical problems were the aliit ination of lead soldering the development of new brazing paste and the minimising of the thickness of the fin material We call ed for technical assistance from Outo 2 Nakamura Jico Co Ltd The Nakamura Jico company was founded in 1929 as a retailer of automobile parts It was a poi authorised supplier to the then Japanese Ministry of Railways in 1934 putation for this product The company has its headquarters in Tokyo a technical laboratory in Takahagi City Ibaragi Prefeclure and manufacturing plants in Tokyo and Qifu City Regional sales offices are located in seven cities in Japan Seven related companies form a group The total annual company revenue is ap proximately 14 billion yen Of this 3 8 bil CuproBraze seminar with focus on 1 production technology A praise worthy initiative sum marised Lars Yllner Manager Technical Development Outo kumpu Copper Strip Sweden The participants had a unique opportunity to acquire all the CuproBraze information they need and could make important lion yen kumpu and as a result decided to perform practical tests of CuproBraze heat ex changers Tieg i ie We have now decided to use the Cupro Braze technology in manufacturing a var iety of heat exchangers and aim at increas ing the value of our sales Of heat ex changers from a current l
45. or use in hcat exchangers other than radiators The process leaves no residues and the strong and solid brazed joints and the high mechanical strength of the ma terial at elevated temperatures are fac tors which are also of great import ance in the manufacture and use of both Charge Air Coolers CAC S ind condensers A CAC is a heat exchanger which cools the air from a turbo Compressor before it enters the combustion cham bers of an engine The lower tempera ture and higher density of the air enter ing the engine makes it possible to burn more fuel at lower temperature thereby generating more power will reduced emissions The CAC must bc perfectly clean inside and must with d Des Aubry Technical Manager Chicago le rer s study a segment of a CuproBrazed CAC stand stresses at elevated temperatures upto 280 C CAC s lubricated using the CuproBraze Process satisfy both these requirements AS a unit in the retrigerant circuit of the AC system of a vehicle the con denser must withstand relatively high internal pressure without leakage and is material must not contribute to cont minadon ofthe refrigerant These characieristics are provided by the use of the CuproBraze Process in manu facturing condensers ft and Bengt Gustafsson Technical Manager Viis When presenting the CuproBraze Pro cess to the automotive industry around the world we found significant inter est in the possible use of
46. oyecto y Conclusiones a Resumen Ejecutivo Antecedentes de la Empresa Radiadores Gallardo Laporte S A Rut 96 803 940 7 fue constituida en Santiago de Chile el 17 de Diciembre de 1996 ante el notario publico Dofia Mercedes Moreno Guemes titular de la Primera Notaria de Santiago anotada en el repertorio N 174 641 e inscrita a fs 33100 N 25 869 del afio 1996 La empresa tiene como giro el Disefio Fabricaci n y Servicio Reparaci n y Mantenci n de Radiadores e Intercambiadores de Calor Radiadores e Panales Automotrices e Industriales e Radiadores de Automotrices e Industriales e Radiadores de Tubos Intercambiables Intercambiadores de Calor e Haz Tubular Carcaza e Enfriadores de Aceite Aire e Sistema de Tubos Aleteados BIBLIOTECA nonem Sintesis del proyecto de Innovaci n i BIBLIOTECA CORFO Ua Cuprobraze es una tecnolog a desarrollada por Outokumpu e ICA Asoc Internacional de Cobre para competir con los Radiadores Aluminio Pl stico que han reemplazando el uso de Cu en el mercado OEM Original Equipment Manufacture y gran parte del Mercado de Reposici n Aftermarket Outokumpu ofrece a Radiadores Gallardo Laporte S A la Transferencia de esta nueva Tecnolog a Esta tecnolog a Mejora las prestaciones de servicio y AMBIENTALES en relaci n al los Radiadores de Cu tradicional y los de Al Los Radiadores de Cobre son m s resistentes a la corrosi n impacto y vibraciones que los de Al
47. plastic brazing paste Old designation P088 iN 3 4 PASTES BY OMG AMERICAS nni tre Sh OC a REMO EQ Oe CURL aja E CE A a EUER x Themoblastic TP00 SONOS int a dod Goa NUR PRO p Re ru C Thermoplastie TP LODOS ra SU LIDO SOMOS ani o le A en EN DU Matata 3 S OTHERS ROR RARE 4 PASTE APPLICATION iciscccscaccciccvisscevccccedvscevsst ctecsccusgustiveeiv tarden arcadas 4 1 TUBE SPRAYING E 42 FIN TIPSGOA TIN Addis 4 3 TUBE TO HEADER JOINT usuwana aa a aa Paga 5 COMPONENTS AND ASSEMBLING eene KOC 5 1 TUBES bai CEDERE TEES 5 2 FAN sas saia aa E a sf dada a Pa ug Te tabs eroe RO PEE NT Gangs o pandas ia A ya 5 3 HEADER sor o Vr iS ai aa prema ER PR tos RIRMO Fa hac 314 5 4 CORE BUILDING AND FIXTURING coc mena BIBLIOTECA GORFU 142 2 RER BS ROK vet ME 6 BRAZING OPERATION cista I EO d da 6 1 GENERAL FURNACE PARAMETERS eene nnne eta inrer ene enn a bd VAMNOSANETE zala salto akro kasa de 6 1 2 Temperature and TIMO aa doii tanc aida a ud a aeons nene a 6 2 FURNACE SELECTION bre gdi da tz hg 6 2 1 Suitable Furnaces ZD NE m Raye na o enje BATMAN 14 6 2 2 Heating SOURCE 6c atas oja Mode ea PNE POWA 75 6 2 3 Nitrogen Consumption address cor 14 05 x GZ A EC pt a a q a cp 7
48. s Charge Air Coolers Se tiene un cabal conocimiento de la tecnologia Cuprobraze su estado de desarrollo y portencial 0000000000000000000000000000000000000000000000000000000 D Resultados Obtenidos y Conclusiones Se fabric maquinaria para la construcci n de procesos y productos piloto e Nuestro proceso de Innovaci n est siendo observado y apoyado por Outokumpu quien durante este a o visitar nuestra Planta Kurt Svanberg Manager Technical Center D Resultados Obtenidos y Conclusiones La tecnologia Cuprobraze todavia no es 100 comercializable en el muy Corto Plazo pero su potencial es enorme sobretodo por el hecho de ser un proceso amistoso con el medio ambiente e Radiadores Gallardo Laporte S A Cree que esta variable dejar en un futuro cercano fuera muchos procesos en el mercado mundial D Resultados Obtenidos y Conclusiones e Se fabric un prototipo de Panal Automotriz con resultados positivos e Se fabric un prototipo de Enfriador de Aceite Industrial para aplicaciones hasta 100 psi con resultados positivos D Resultados Obtenidos y Conclusiones Se fabricara un prototipo desarrollando Charge Air Cooler en Cobre Actualmente son en Aluminio el que ser evaluado por Outokumpu Se seguir investigando para desarrollar un prototipo de enfriadores de aceite para presiones de trabajo mayor a 100 psi y hasta 350 psi D Impactos del Proyecto Se tiene acceso a nueva
49. to Cuprobraze de Brazado a Rizo Mesa de Armado Panal Mesa de Armado Panal antes de tratamiento t rmico Horno Outokumpu Suecia Laboratorio Proyecto Cuprobraze Fabricaci n de Colectores Punzonadora de Control num rico para fabricar colectores Outokumpu Suecia Laboratorio Proyecto Cuprobraze 0000000000000000000000000000000000000000000000000000000 Entrada del Horno Se abre el carro para insertar Panal de Radiador Cuprobraze en el Horno Outokumpu Suecia Laboratorio Proyecto Cuprobraze Precalentador Panal Precalentador Panal antes de entrar al horno Se estaba probando en varias etapas para tomar los 600 C Outokumpu Suecia Laboratorio Proyecto Cuprobraze Estanque de Nitr geno Estanque con Nitr geno para inyectar al Horno de atm sfera controlada Outokumpu Suecia Laboratorio Proyecto Cuprobraze Etapa Inyecci n Nitrogeno Etapa en que se inyecta nitrogeno al horno Outokumpu Suecia Laboratorio Proyecto Cuprobraze Probando Radiador Industrial ge d e Se est n probando PP a Radiadores z sd Cuprobraze para Camiones con estanques apernados Todav a hay problemas de filtraci n en la uni n colector tubos Outokumpu Suecia Laboratorio Proyecto Cuprobraze Ope e Eeqiue sogn eyed ejeqn se eujsnpu seJ0 99 09 Jedue s3 eJed zuje ELIJSNpPU sopeipey esed seje v ep eJopeduiejs euinbe w e W S euode7 op
50. wn gauging High gt performance coatings further improve corrosion resistance and make down gauging possible without risks for corrosion problems ta XT The high performance coating methods are electro phoretic coating and a E type of multi nozzle powder coating The coatings cover the entire external radiator surface not only about 10 of it like conventional cosmetic spray coating They clearly prolong the lifetime of copper brass radiators The technology for this type of coating is commercially available WARE Tn The main process stages in these methods are pre cleaning coating and curing 7 Immediately after CuproBraze process the radiators are usually so clean ci no pre cleaning before painting is needed LS 3 Mu These coating methods for radiators are able to coat to low thickness levels Bona 8 micrometers 0 3 mils which means that the methods do not adversely affect the thermal performance The methods are also environmentally friendly E mue 5 The total cost per radiator is somewhat higher than for spray painting because the entire radiator surface is coated By accepting the reasonable cost increase a longer service ife weight savings and environmental and safety benefits will be achieved Ee s t RZA y ef ECA TM as 9 Repairing 8 1 Soft soldering CuproBraze radiators can be repaired with lead free soft solders In CuproBraze amp process copper tin
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