CN204035770U - 一种热交换器 - Google Patents

一种热交换器 Download PDF

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CN204035770U
CN204035770U CN201320273019.4U CN201320273019U CN204035770U CN 204035770 U CN204035770 U CN 204035770U CN 201320273019 U CN201320273019 U CN 201320273019U CN 204035770 U CN204035770 U CN 204035770U
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shell
heat exchanger
tube sheet
liquid
pipe
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米夏埃尔·威尔之
斯帕索耶·伊尼亚托维奇
鲁迪格尔·科尔布林
克劳斯·邦纳特
斯特凡·费尔伯
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Mahle Behr GmbH and Co KG
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    • 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
    • B23K31/00Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/02Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
    • 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
    • B23K9/00Arc welding or cutting
    • B23K9/16Arc welding or cutting making use of shielding gas
    • B23K9/173Arc welding or cutting making use of shielding gas and of a consumable electrode
    • 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
    • B23K35/001Interlayers, transition pieces for metallurgical bonding of workpieces
    • B23K35/002Interlayers, transition pieces for metallurgical bonding of workpieces at least one of the workpieces being of light metal
    • 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
    • B23K35/001Interlayers, transition pieces for metallurgical bonding of workpieces
    • B23K35/004Interlayers, transition pieces for metallurgical bonding of workpieces at least one of the workpieces being of a metal of the iron group
    • 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
    • B23K9/00Arc welding or cutting
    • B23K9/09Arrangements or circuits for arc welding with pulsed current or voltage
    • B23K9/091Arrangements or circuits for arc welding with pulsed current or voltage characterised by the circuits
    • B23K9/092Arrangements or circuits for arc welding with pulsed current or voltage characterised by the circuits characterised by the shape of the pulses produced
    • 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
    • B23K9/00Arc welding or cutting
    • B23K9/12Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
    • B23K9/124Circuits or methods for feeding welding wire
    • B23K9/125Feeding of electrodes
    • 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
    • B23K9/00Arc welding or cutting
    • B23K9/23Arc welding or cutting taking account of the properties of the materials to be welded
    • B23K9/232Arc welding or cutting taking account of the properties of the materials to be welded of different metals
    • 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
    • F28D7/00Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
    • F28D7/16Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged in parallel spaced relation
    • F28D7/1684Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged in parallel spaced relation the conduits having a non-circular cross-section
    • 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
    • F28F21/082Heat exchange elements made from metals or metal alloys from steel or ferrous alloys
    • F28F21/083Heat exchange elements made from metals or metal alloys from steel or ferrous alloys from stainless steel
    • 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
    • F28F9/00Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02Header boxes; End plates
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02Header boxes; End plates
    • F28F9/0219Arrangements for sealing end plates into casing or header box; Header box sub-elements
    • 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
    • B23K2101/00Articles made by soldering, welding or cutting
    • B23K2101/04Tubular or hollow articles
    • B23K2101/14Heat 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
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/18Dissimilar materials
    • B23K2103/20Ferrous alloys and aluminium or alloys thereof

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  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Plasma & Fusion (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Coating With Molten Metal (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Arc Welding In General (AREA)

Abstract

本实用新型提供一种热交换器,其外壳和至少一个管板之间形成材料锁合连接,该热交换器具有多根引导第一液体的管子,所述管子的端部区域分别容纳在一管板中,该热交换器还具有一环绕管子的外壳,其中,第二液体可以流过该外壳,且第二液体可环绕管子流动,其中,管板插入外壳中,以使引导第一液体的第一管道与引导第二液体的第二管道隔离,所述外壳基本上由不锈钢制成,所述管板和所述多根引导第一液体的管子基本上由铝或铝合金制成,由于管板和外壳在外壳内部形成材料锁合连接,从而使它们之间的连接更简单,这是因为管板的形状与外壳的内部轮廓相匹配。

Description

一种热交换器
技术领域
本发明涉及一种用于在不锈钢制成的第一组件与铝或铝合金制成的第二组件之间建立材料锁合连接的方法。 
此外,本发明还涉及一种热交换器,其外壳和至少一个管板之间形成材料锁合连接。尤其涉及一种用于冷却内燃机废气的管束热交换器,该热交换器具有多根引导第一液体的管子,这些管子的端部区域容纳在管板中;该热交换器还具有一环绕这些管子的外壳,其中,第二液体可以流过外壳,且该第二液体可环绕管子流动。其中,该管板以这样的方式插入外壳中,即,使得引导第一液体的第一管道与引导第二液体的第二管道隔离。 
背景技术
在目前的现有技术中,废气热交换器通常完全由不锈钢制成。这是因为废气的温度和废气的腐蚀性对热交换器的要求较高。目前,此类不锈钢热交换器是通过焊接工艺连接的,比如通过激光焊接或MAG(熔化极活性气体保护焊)焊接连接。 
可选地,根据现有技术,热交换器由不锈钢组件和铝组件组成,该不锈钢组件和铝组件通过拧紧的法兰连接,也就是通过型锁合连接,这是因为,迄今为止,使用已知的热连接工艺,比如MIG(惰性气体保护焊/)/MAG焊接或冷金属过渡工艺,无法实现铝和不锈钢之间的材料锁合连接。 
上述型锁合连接方式必须使用额外的组件(比如密封垫),此外,这种连接方式对组件公差范围的要求特别高,以确保各组件之间的密封连接。 
出于技术原因,在热交换器的使用过程中,越来越需要在铝和不锈钢之间形成材料锁合连接,因此,有必要提供一种连接铝组件和不锈钢组件的材料锁合连接方法。 
在这一方面,现有技术是特别不足的,因为至今为止不存在任何能够实现铝组件和不锈钢组件的材料锁合连接的合适方法。 
发明内容
因此,本发明的目的在于提供一种方法,以实现不锈钢与铝或铝合金之间的材料锁合连接。 
有利的是,为了在不锈钢制成的第一组件与铝或铝合金制成的第二组件之间建立材料锁合连接,进行以下步骤: 
在不锈钢组件上涂上镍层; 
在涂有镍层的不锈钢组件上涂上铝层; 
以这样的方式设置涂有镍层和铝层的不锈钢组件与铝组件或铝合金组件的相对位置,即,使第一组件和第二组件的部分区域设置为相互平行,并且相互面接触地抵靠在一起或者相互之间形成0mm至5mm的间隙; 
通过冷金属过渡工艺在涂层的不锈钢组件与铝或铝合金组件之间建立材料锁合连接。 
通过使用冷金属过渡工艺,可以实现两种材料之间的精确连接。在此,相应组件上产生的热量非常低,从而有利于进一步加工。此外,由于这种工艺的速度较快,因而非常适合在大规模生产中使用。这种工艺可以将较宽的间隙连接起来,从而可以使用该方法连接具有相对较大公差的两个组件。 
在镍层上直接涂上铝层也会带来有益效果。这样将在不锈钢表面上形成双层涂层,从而有利于冷金属过渡工艺的实施,也有利于建立耐久的材料锁合连接。 
进一步地,通过电镀形成不锈钢组件的镍层和/或铝层。电镀可形成不同的涂层厚度,从而有利于与载体表面形成良好的连接。因此,可根据期望的用途对涂层进行调整。 
在可选的实施例中,有利的是,使用MIG焊接法取代冷金属过渡工艺。 
同样有利的是,上述组件为热交换器的外壳和管板。管板和外壳之间形成材料锁合连接,使得外壳相对于外部密封,从而在外壳内部形成了第二流通管道。 
此外,优选这样的热交换器,即,其外壳与至少一个管板之间形成材料锁合连接。尤其是一种用于冷却内燃机废气的管束热交换器,该热交换器具有多根引导第一液体的管子,这些管子的端部区域分别容纳在管板中;该热交换器还具有一环绕这些管子的外壳,其中,第二液体可以流过该外壳,该第二液体可环绕管子流动。其中,管板以这样的方式插入外壳中,即,使得 引导第一液体的第一管道与引导第二液体的第二管道隔离。其中,外壳基本上由不锈钢制成,管板和引导第一液体的多根管子基本上由铝或铝合金制成。 
有利的是,外壳与管板之间的连接通过热连接工艺以材料锁合的方式实现。从而确保上述连接具有足够好的密封效果,这样便无需采用额外的密封措施。 
根据可选的实施例,优选的是,外壳上涂有镍层和铝层,该镍层和铝层位于外壳与管板相连的连接部位,上述连接部位位于外壳的端部区域。不锈钢外壳上的涂层有利于与铝材料建立连接,并且有助于保持更好的连接效果。 
此外,有利的是,外壳和管板在外壳内部形成材料锁合连接。由于管板和外壳在外壳内部形成材料锁合连接,从而使它们之间的连接更简单,这是因为管板的形状与外壳的内部轮廓相匹配。 
附图说明
下面参照附图详细描述本发明的实施例。其中: 
图1示出了热交换器,尤其是管束热交换器的立体图; 
图2示出了外壳与管板之间的连接部位的局部剖视图; 
图3示出了用于显示各工艺步骤的流程图。 
具体实施方式
图1示出了热交换器1的立体图。特别地,示出的热交换器1为管束热交换器,其主要包括外壳2。在外壳2的内部设有多根管子4,第一液体可通过这些管子4流经热交换器1。这些管子4的端部区域容纳在管板3中。 
在热交换器1的两端处,管板3与外壳2连接在一起。在此处所示的示例中,管板3焊接至外壳2的内表面。焊缝7沿着外壳2的内表面上的管板3呈环形。 
另外,热交换器1的外壳2具有冷却剂入口6以及冷却剂出口5。一额外的第二液体可通过这两个开口流过外壳2,其中该液体环绕外壳2内部的管子4以形成绕流。 
图1未示出其余的连接元件,这些连接元件可以设置在热交换器1的外壳2的侧面,以便将通过管子4在外壳2的内部中流动的第一液体引导至外壳2中,或者将该第一液体从外壳2中排出。 
图1所示的热交换器1主要由两种材料制成。热交换器1的外壳2主要由不锈钢制成。管板3以及容纳在管板中的管子4由铝或铝合金制成。使用铝或铝合金制成管板3和管子4,是为了降低热交换器1的整个系统的重量。 
图2示出了连接部位8的详细视图,该连接部位8位于管板3和外壳2之间。可以看出管板3特别地设置在外壳2的其中一个端部区域中。正如在对图1的描述中所提及的,管板3焊接至外壳2,其焊缝环绕在外壳2的内表面上。在图2的剖视图中可以清楚地看出其焊缝7。 
在此处所示的示例中,管板3设置为邻近外壳2的端部区域,且管板3与外壳2面接触。但是,在可选的实施例中,管板3还可以设置在其它位置,即,可以设置在热交换器1或者外壳2的中间部位,这样特别有利于确保足够的边缘偏移,从而将焊缝7所占的空间和/或散发的热量降到最低。 
类似地,在此处所示的示意图中,管板3自由地设置在外壳2的内部。在其它实施例中,同样可以想到,外壳2的内侧具有一环形边缘或凸肩,在环形边缘或凸肩上设置管板3。 
冷金属过渡工艺以及MIG焊接工艺均也可以连接两个相互需要连接的组件之间的一定间隙。在可选的实施例中,还可以想到的是,在将管板和外壳连接在一起之前,管板和外壳并不设为相互面接触,而是在管板和外壳之间形成一约0mm至3mm的间隙。 
图3示出了一个流程图,包含四个工艺步骤9、10、11和12,用于说明不锈钢与铝或铝合金之间的连接方法。为了连接管板3和外壳2,在根据本发明的实施例中,通过冷金属过渡工艺连接管板3和外壳2。为了确保冷金属过渡工艺能够将铝材料或铝合金连接至不锈钢,必须对不锈钢组件进行预处理。 
出于这一原因,外壳2在连接部位8的内部区域,尤其是在焊缝7的区域,设有涂层。 
为此,在第一工艺步骤9中,在不锈钢组件上喷涂一镍层。优选地,该镍层涂在之后需要形成连接的区域。然而,可以想到的是,涂层表面可以延伸到上述区域以外的区域。 
在第二工艺步骤10中,在第一工艺步骤9中已经涂有镍层的不锈钢组件上喷涂一铝层。优选地,该铝层也限制为涂在不锈钢件和铝件之间的连接区域,其中,铝层直接喷涂至第一工艺步骤9中所喷涂的镍层上。在完成第一工艺步骤9和第二工艺步骤10后,则外壳2具有两层相互重叠的涂层。 
按具体用途,可以通过电镀处理将上述两层涂层喷涂到外壳2的内表面上。 
在外壳2的内表面涂上涂层之后,执行第三工艺步骤11,在该步骤中设置上述涂有镍和铝涂层的不锈钢组件与铝或铝合金组件的相对位置。以这样的方式对上述涂有镍层和铝层的不锈钢组件以及铝组件或铝合金组件进行设置,即,使它们在端面具有边缘偏移。该边缘偏移为焊缝7提供空间,并将散热降到最低。 
在所示的示例性实施例中,管板3及其容纳的管子4设置在外壳内部。 
然后在第四工艺步骤12中,通过冷金属过渡工艺实现不锈钢组件与铝或铝合金组件的材料锁合连接。 
作为可代替冷金属过渡工艺的另一种选择,可以考虑使用MIG焊接法。为此,在外壳2的内表面进行与使用冷金属过渡工艺应用中相同的预处理。 

Claims (4)

1.一种热交换器,其外壳(2)和至少一个管板(3)之间形成材料锁合连接,该热交换器(1)具有多根引导第一液体的管子(4),所述管子(4)的端部区域分别容纳在一管板(3)中,该热交换器(1)还具有一环绕管子(4)的外壳(2),其中,第二液体可以流过该外壳(2),且第二液体可环绕管子(4)流动,其中,管板(3)插入外壳(2)中,以使引导第一液体的第一管道与引导第二液体的第二管道隔离,其特征在于,所述外壳(2)基本上由不锈钢制成,所述管板(3)和所述多根引导第一液体的管子(4)基本上由铝或铝合金制成。 
2.根据权利要求1所述的热交换器,其特征在于,所述热交换器(1)为一种用于冷却内燃机废气的管束热交换器。 
3.根据权利要1所述的热交换器,其特征在于,外壳(2)在其与管板(3)相连的连接部位(8)涂有镍层和铝层,该连接部位(8)位于外壳(2)的端部区域。 
4.根据权利要求1至3中任一项所述的热交换器,其特征在于,外壳(2)和管板(3)在外壳(2)内部形成材料锁合连接。 
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