CN1244249A - 铝基热交换器芯及其制造方法 - Google Patents

铝基热交换器芯及其制造方法 Download PDF

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CN1244249A
CN1244249A CN98801950A CN98801950A CN1244249A CN 1244249 A CN1244249 A CN 1244249A CN 98801950 A CN98801950 A CN 98801950A CN 98801950 A CN98801950 A CN 98801950A CN 1244249 A CN1244249 A CN 1244249A
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heat exchanger
zinc
fin
silicon
aluminium base
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铃木敏弘
田中庸彦
小笠原明德
冲义人
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Rio Tinto Alcan International Ltd
Nippon Light Metal Co Ltd
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Nippon Light Metal Co Ltd
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F21/00Constructions of heat-exchange apparatus characterised by the selection of particular materials
    • F28F21/08Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28DHEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D1/00Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
    • F28D1/02Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
    • F28D1/04Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits
    • F28D1/053Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight
    • F28D1/0535Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight the conduits having a non-circular cross-section
    • F28D1/05366Assemblies of conduits connected to common headers, e.g. core type radiators
    • F28D1/05383Assemblies of conduits connected to common headers, e.g. core type radiators with multiple rows of conduits or with multi-channel conduits
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00Soldering, e.g. brazing, or unsoldering
    • B23K1/0008Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
    • B23K1/0012Brazing heat exchangers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0222Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in soldering, brazing
    • B23K35/0244Powders, particles or spheres; Preforms made therefrom
    • B23K35/025Pastes, creams, slurries
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/28Selection of soldering or welding materials proper with the principal constituent melting at less than 950 degrees C
    • B23K35/286Al as the principal constituent
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F1/00Tubular elements; Assemblies of tubular elements
    • F28F1/10Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses
    • F28F1/12Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element
    • F28F1/126Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element consisting of zig-zag shaped fins
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F21/00Constructions of heat-exchange apparatus characterised by the selection of particular materials
    • F28F21/08Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
    • F28F21/081Heat exchange elements made from metals or metal alloys
    • F28F21/084Heat exchange elements made from metals or metal alloys from aluminium or aluminium alloys
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F21/00Constructions of heat-exchange apparatus characterised by the selection of particular materials
    • F28F21/08Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
    • F28F21/089Coatings, claddings or bonding layers made from metals or metal alloys
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/08Non-ferrous metals or alloys
    • B23K2103/10Aluminium or alloys thereof
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/28Selection of soldering or welding materials proper with the principal constituent melting at less than 950 degrees C
    • B23K35/286Al as the principal constituent
    • B23K35/288Al as the principal constituent with Sn or Zn
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/30Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/36Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest
    • B23K35/3601Selection of non-metallic compositions, e.g. coatings, fluxes; Selection of soldering or welding materials, conjoint with selection of non-metallic compositions, both selections being of interest with inorganic compounds as principal constituents
    • B23K35/3603Halide salts
    • B23K35/3605Fluorides

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  • Details Of Heat-Exchange And Heat-Transfer (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Coating With Molten Metal (AREA)
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  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
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Abstract

本发明提供一种其耐腐蚀性能和钎接能力相当于或者高于惯用的对应产品的热交换器芯。在作为热交换器管的挤压扁平管(4)的外表面上涂覆从硅和氟类熔剂的混合物得来的钎焊焊剂(7);制备由铝基含锌材料制成的散热片(5);然后,在给定温度下加热挤压扁平管(4)和散热片(5),将两者带入彼此钎接的关系,并且硅和锌的混合扩散层(8)形成在挤压的扁平管(4)的外表面上。

Description

铝基热交换器芯及其制造方法
本发明涉及铝基热交换器芯及其制造方法。更具体来说,本发明涉及这样的铝基热交换器芯,其中,例如铝基扁平的热交换器管和铝基散热片通过利用钎焊焊剂以钎焊关系彼此固定在一起。本发明还涉及用于制造这种热交换器芯的方法。
一般来说,利用由铝或者铝合金(此后称为铝基的)构成的热交换器管和铝基散热片彼此钎焊起来制成的某种铝基散热器已经被广泛采用。另外同时也是为了获得改进的热交换效率,已经采用挤压的扁平管作为热交换器管,该挤压的扁平管是由铝基材料挤压成形得到的。
为了使最终得到的热交换器是抗腐蚀的,通常使锌(Zn)粘附在扁平的热交换器管的外表面上,接着在钎焊期间随着加热锌扩散在这样的扁平管的外表面上,随后在其上形成锌的扩散层。另外,由钎焊板制备散热片,而钎焊板是从镀以含锌的钎焊材料即钎焊焊剂的那些材料中选择的。
然而,这样的用于散热片制备的钎焊板如与未镀以钎焊材料的散热片坯料相比是昂贵的。而且,由于在其表面上镀以钎焊材料,钎焊板将导致散热片加工轧机的迅速腐蚀,从而需要对这样的加工轧机经常抛光。作为另外的问题是,在制造隔栅时往往发生烧化和焊瘤,结果,加工好的热交换器芯质量降低。
为了改进扁平热交换器管的耐腐蚀性能,已经采用了这样的一种方法,其中,例如采用锌酸盐方法或者锌的电弧喷镀方法使锌提前粘附于这种扁平管的外表面上,然后在钎焊的过程中形成锌的扩散层,因而扁平管通过损失的电极得以防止腐蚀。然而,这种方法留下的问题是,锌的粘附过程相当漫长和耗时。
另一方面,已知一种方法,其中,使用非镀以钎焊料的散热片坯料,并且其中,对扁平热交换器管钎焊以从铝(Al)和硅(Si)得来的粉末状硅-铝合金。这样的已知方法需要镀以极大量的粉末状的硅-铝合金,因而造成与成本和组装有关的那些缺点。按照另外一种已知方法,扁平热交换器管是由镀以钎焊料的电焊管来制备的。然而,在该最后的方法中,当管变得多孔时,要求在这样的管子的内部布置一种镶嵌件,这将造成加工步骤增加,因而制造成本和材料成本增加。
本发明在鉴于上述的情况下制造和完成。本发明的一个目的是提供一种热交换器芯,其是从利用无需提前粘附锌的热交换器管和不镀以钎焊焊剂的散热片坯料而得来的,并且展现出相当于或者高于惯用对应产品的耐腐蚀性能和钎接能力。本发明的另外的目的是提供一种用于制造这种热交换器芯的方法。
为了达到上述的目的,在权利要求1中引述的本发明涉及一种铝基热交换器芯,其中,铝基的热交换器管和铝基的散热片通过利用钎焊焊剂而以钎接的关系彼此被固定在一起,其特征在于,由硅和锌的混合物构成的混合扩散层形成在热交换器管的外表面上,并且散热片由含锌的铝基材料制成,该锌用于构成所述的混合扩散层的一部分。
另外,在权利要求3中引述的本发明涉及一种用于制造铝基热交换器芯的方法,其中,铝基热交换器管和铝基散热片通过利用钎焊焊剂以钎接的关系彼此固定,其特征在于,该方法包括:在热交换器管的外表面上涂覆从硅和氟类熔剂的混合物得来的钎焊焊剂,制备由铝基含锌材料制成的散热片,随后在给定温度下加热热交换器管和散热片,借此,使热交换器管和散热片成彼此钎接的关系并且在热交换器管的外表面上形成硅和锌的混合扩散层。在该实例中,在由硅和锌组成的并且位于热交换器表面上的混合的扩散层中,硅的最大浓度在0.5-1.5%的范围内,而锌的在0.4-3.0%的范围内。
在本发明中,上述的热交换器管可以是任选的形状,只要其是铝基的即可。最好是,该管是铝基的挤压扁平管并且设置有多个用于供应加热介质的通道。另外所希望的是,在上述的散热片中的锌的浓度可以在1-5%的范围内(权利要求2)。
根据本发明,硅和氟类熔剂的混合物被用作钎焊焊剂,结果是,热交换器管不要求锌在先粘附在其上,并且未镀以钎焊焊剂的含锌的散热片坯料可以使用得益。由此产生的散热片零件在钎焊期间借助钎焊焊剂而部分熔化,因此,含在散热片中的锌在热交换器管的外表面上扩散,从而在其上形成硅和锌的混合扩散层。
因此,锌扩散层可以形成在热交换器管的外表面上,而无需现今管子在先所需要的锌的粘附。这容许热交换器芯易于实施,同时有极好的耐腐蚀性能和钎接能力。另外有利的是,散热片不需要镀以钎焊焊剂,因而可确保构成容易并且可避免烧化和焊瘤,同时最终生产的热交换器芯具有高的质量。还可以获得改进的生产率和节省费用。
图1以透视图示出了在其内装配了本发明的热交换器芯的一种形式的热交换器的重要部分。
图2是示出体现本发明的每个挤压扁平管和波纹形散热片的透视图。
图3是示出钎焊焊剂被涂覆在本发明的挤压扁平管上的方式的横截面图。
图4是根据本发明热交换器管和散热片被带入彼此钎接关系之方式的局部放大的横截面图。
在这些视图中,标号4指的是挤压扁平管(热交换器管),5指的是波纹形散热片,6指的是热交换器芯,7指的是钎焊焊剂,8指的是硅和锌的扩散层。
下面参照附图对本发明的几个实施例进行描述。
图1是示出在其内装配了本发明的热交换器芯的一种形式的热交换器的重要部分的透视图。
上述热交换器的构成有:一对以隔开对置姿势放置并且具有一个加热介质进口1或者一个加热介质出口2的联管箱3;多个用作热交换器管的挤压扁平管4,该些挤压扁平管彼此平行布置并且与联管箱3相连通;和介于挤压扁平管4之间的诸如波纹形散热片5的散热片。在如此组装的热交换器中,联管箱3和挤压扁平管4由铝基材料通过挤压成形而构成,而波纹形散热片5通过使铝基板材弯曲成交替的沟槽和脊部即弯曲成波纹形的构形而构成。联管箱3,挤压扁平管4和波纹形散热片5通过利用钎焊焊剂(钎焊材料)而成为彼此整体的钎接关系,从而制成热交换器。
在那种情况下,由挤压扁平管4和波纹形散热片5组成的热交换器芯6是由未以粘附锌预先处理的那些铝基挤压扁平管(例如JIS A1050)构成的,而波纹形散热片5是由未镀以钎焊材料的铝基含锌板材构成的。作为钎焊材料,粉末状的硅(Si)和粉末状的氟类熔剂的混合物,或者粉末状的硅,粉末状的锌和粉末状氟类熔剂的混合物已被公用。这里,氟类熔剂的组成可以是例如KA1F4,K2A1F5.H2O或者K3A1F6。这类氟类熔剂是人们所希望的,因为它不同于氯化物,因而可避免对铝的腐蚀。硅与熔剂的比(按重量)设定为硅∶熔剂=1∶2。
为了制造上述的热交换器芯6,第一加工步骤在于制备,如从图2可见,铝基的和在其内限定有多个用于流动加热介质通道的挤压扁平管4和弯曲成波纹形布置并且含锌的波纹形散热片5。为此目的,波纹形散热片5利用加工轧机从将含锌的铝基板材(例如JIS A3NO3)弯曲成波纹形而得到。在该实例中,加工轧机比镀以钎焊材料的钎焊板不易受腐蚀。另外的优点是,既使当在散热片上加工安装隔栅等时也不会发生烧化和焊瘤。这有助于提高散热片的质量。
之后,钎焊焊剂7利用诸如热塑性丙烯酸树脂等粘结剂而施加在挤压的扁平管4的表面上,如图3所示。该钎焊焊剂在挤压的扁平管4上的施加可以通过例如喷镀粘结剂和钎焊焊剂的混合稀浆来实现,或者这样来实现,即将挤压的扁平管4浸入粘结剂和焊剂的混合稀浆中然后将管子从稀浆中垂直地拉出来,以便去掉过多的稀浆。
接着,如此载有焊剂的挤压扁平管4和含锌的波纹形散热片5利用工具被彼此结合和固定在一起,或者通过连接在联管箱3上而被彼此固定。通过在加热炉等中在例如高于590℃的预定温度下的随后加热,焊剂被熔化而使挤压的扁平管4和波纹形散热片5成为彼此整体的钎接关系。在焊接过程中,波纹形散热片的部分通过焊剂的作用而熔化,结果,在波纹形散热片5中含有的锌在挤压扁平管4的整个外表面上扩散,最终与含在焊剂中的硅相互配合而在扁平管4的整个外表面上形成硅和锌的扩散层8。挤压扁平管4和波纹形散热片5利用介于其间的铝-硅-锌合金的角焊缝进一步被彼此固定成整体的连接关系。在硅和锌的扩散层8形成在挤压扁平管4的整个外表面上的情况下,最终合成的热交换器芯6是耐腐蚀的。
现在在这里,根据与现有技术的铝基热交换器芯的焊接能力和耐腐蚀性的比较,就对本发明的热交换器芯的那些指标进行评价所做的那些试验提供解释。
Θ原料
*挤压扁平管
(1)材料:JIS A1050
         :JIS A105锌的电弧喷镀
           (锌的指标量8克/平方米)
         :NE合金(改进的A1050合金)(成
         份:0.05%硅,0.18%铁,0.4%铜,
         0.02%锌和0.04%锆)
(2)形状:外部尺寸(宽×壁厚)=19.2毫米×
             1.93毫米
             (一侧壁厚:0.4毫米)
*散热片
(1)材料:坯料(JIS A3NO3+0-4.0%锌量)
         钎焊板(A4343+1.0%锌/3NO3+
         1.5%锌/A4343+1.0%锌)
(2)形状:(宽×壁厚)=21.1毫米×0.1毫米
*钎焊焊剂
(1)粉末状硅+粉末状氟类熔剂+粘结剂
粘结总量:16克/平方米
Θ钎焊工况
通行的工况:
    在氮气中(氮量:40立方米/小时)
    加热速度:30℃/分钟
关于比较实例1和2和实例1-4(其中,上述的挤压扁平管4通过利用上述的钎焊焊剂与散热片坯料《锌含量0-4.0%》被固定钎接)和关于比较的钎焊方法1和2(通行的钎焊方法)的详细情况示于表1中。在挤压的扁平管4和散热片之间的接合部被切割和检测。所获得的钎接能力的结果列于表2中。
利用CASS试验(JIS H8681)对加工好的钎接产品的耐腐蚀性能作了进一步的评价。其结果列于表2中。
另外,利用X射线显微分析器(XMA)对挤压的扁平管4的横截面作了探测,以便观察锌和硅的扩散状态。其结果列于表2中。
表1
散热片材料 挤压扁平管 钎焊焊剂
比较实例1 散热片坯料(锌含量;0%) A1050 粉末状硅+钎焊熔剂+粘结剂;16g/m2
比较实例2 散热片坯料(锌含量;0.8%) A1050 粉末状硅+钎焊熔剂+粘结剂;16g/m2
实例1 散热片坯料(锌含量;1.2%) A1050 粉末状硅+钎焊熔剂+粘结剂;16g/m2
实例2 散热片坯料(锌含量;2.0%) A1050 粉末状硅+钎焊熔剂+粘结剂;16g/m2
实例3 散热片坯料(锌含量;2.0%) NE合金(0.4%含铜合金) 粉末状硅+钎焊熔剂+粘结剂;16g/m2
实例4 散热片坯料(锌含量;5.0%) A1050 粉末状硅+钎焊熔剂+粘结剂;16g/m2
比较钎焊方法-1 散热片坯料(锌含量;1.5%) A1050 粉末状硅+钎焊熔剂+粘结剂;16g/m2
比较钎焊方法-2 散热片坯料(锌含量;1.5%) A1050+锌喷涂(锌的指标量;8g/m2) 粉末状硅+钎焊熔剂+粘结剂;16g/m2
表2
钎接能力 扩散状态 根据CASS试验法对耐腐蚀性能的评价结果
锌扩散状态 硅扩散状态 500小时 100小时 1500小时
比较实例1 表面浓度;零扩散深度;零 表面浓度;1.1%扩散深度;70μm × ×
比较实例2 表面浓度;0.3%扩散深度;76μm 表面浓度;1.0%扩散深度;68μm ×
实例1 表面浓度;0.6%扩散深度;72μm 表面浓度;0.8%扩散深度;78μm
实例2 表面浓度;1.1%扩散深度;74μm 表面浓度;0.9%扩散深度;72μm
实例3 表面浓度;1.0%扩散深度;79μm 表面浓度;1.0%扩散深度;67μm
实例4 表面浓度;2.2%扩散深度;80μm 表面浓度;0.8%扩散深度;73μm
比较钎焊方法-1 表面浓度;零扩散深度;零 表面浓度;零扩散深度;零 × × ×
比较钎焊方法-2 表面浓度;2.3%扩散深度;84μm 表面浓度;零扩散深度;零 ×
测量了扩散深度的地方:两个散热片之间◎:点蚀深度200μm或小于○:无空穴(点蚀深度介于200μm之上和400μm之下之间)×:空穴
上述的试验结果表明,在实例1-4中所获得的所有钎接状态比采用现行采用的钎焊板的热交换器芯的更好,并且在实例1-4中的钎接百分数大于99.5%。
根据利用CASS试验对钎接产品的检查发现,在达到1500小时的试验时间长度时比较实例1和2以及现行的钎焊方法1和2形成了空穴,而实例1-4的产品既使在这样长的试验时间过去之后也证明没有这样的空穴。
另外,根据对锌和硅的扩散状态(表面浓度和扩散深度)的检查,在实例1-4中的锌的扩散状态是0.6%-2.2%和72-80微米(μm),而硅的扩散状态是0.8%-1.0%和67-78微米。
从上述的试验已经发现,利用粉末状的硅和氟类熔剂的混合物构成的钎焊焊剂从彼此钎接起来的铝基的和1.2%-4%含锌量的散热片和铝基的并且省略提前粘附锌的挤压扁平管获得的热交换器芯能够提供相当于或者高于现有技术中现行使用的热交换器芯的钎接能力和耐腐蚀性能。虽然没有在上述的试验结果中给出,但是在散热片材料中少于1%的锌含量会产生低于0.4%的锌的表面扩散浓度,因此将导致锌扩散层的不足的阳极作用。相反,高于5%的锌的较高含量将使散热片材料本身显著腐蚀,结果,成品的热交换器使用寿命短并且成品的散热片将降低其高温下的材料强度,因此当钎焊时往往会翘曲。因此,在散热片材料中锌以1.0%-5.0%的含量存在的情况下,钎接能力和耐腐蚀性能可以达到诸如相当于或者高于通行的热交换器芯的那些值。
虽然其在上述的试验结果中没有被展示出来,但是从该一系列的试验结果中还是可以发现,添加的锌量越大,可以以较高的浓度形成锌的扩散层,因而可预计有较大的耐腐蚀性能,并且因为硅扩散层关系到挤压扁平管这一方面的点蚀诱发可能性,所以可以比在没有硅扩散层的挤压扁平管方面达到较高的耐腐蚀性能。
如上说明和展示的,本发明能够使硅和氟类熔剂的混合物用作钎焊焊剂,因此热交换器管不要求提前粘附锌,并且含有锌但是不镀以钎焊焊剂的散热片坯料可以用于形成散热片。散热片零件当经受钎焊焊剂的作用时于是熔化,因此含在散热片中的锌在热交换器管的外表面上扩散,因而起着在该外表面上形成由硅和锌的混合物构成的扩散层的作用。
因此,锌的扩散层可以形成在热交换器管的外表面上而无需针对现今的管子进行在先所需要的锌的粘附。这又容许热交换器芯容易地具有高的耐腐蚀性能和高的钎接能力。另外的优点是,散热片无需镀以钎焊焊剂,因而可确保容易的施工性能,并且可避免烧化和焊瘤,最终使热交换器芯具有高的质量。可做得到的高生产率同时节省费用是另外的一个优点。

Claims (3)

1.一种铝基的热交换器芯,其中,铝基的热交换器管和铝基的散热片通过利用钎焊焊剂而以钎接的关系彼此被固定在一起,其特征在于,由硅和锌的混合物构成的混合扩散层形成在所述的热交换器管的外表面上,并且所述的散热片由含锌的铝基材料制成,该锌用于构成所述的混合扩散层的一部分。
2.如权利要求1所述的铝基热交换器芯,其特征在于,在所述的散热片中锌的浓度在1-5%的范围内。
3.一种生产铝基热交换器芯的方法,其中,铝基热交换器管和铝基散热片通过利用钎焊焊剂以钎接的关系彼此固定,其特征在于,该方法包括:在所述的的热交换器管的外表面上涂覆从硅和氟类熔剂的混合物得来的钎焊焊剂,制备由铝基含锌材料制成的所述的散热片,随后在给定温度下加热所述的热交换器管和所述的散热片,借此,使所述的热交换器管和所述的散热片成彼此钎接的关系并且在所述的热交换器管的外表面上形成硅和锌的混合扩散层。
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