JPH1192848A - Heat exchanger core made of aluminum and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a heat exchanger core having corrosion-resistance and brazing properties equal to or above those of the conventional one by using a heat exchanger free from the need of the coating of Zn in advance and a fin clad with no composition for brazing. SOLUTION: An extruded flat tube 4 as a heat exchanger tube is formed of a member contg. 0.01 to 0.6% copper element, and the balance substantial aluminum, the surface of this extruded flat tube 4 is coated with a composition for brazing composed of silicon and fluorine base flux, a member made of aluminum contg. zinc is used for a fin 5, and the extruded flat tube 4 and the fin 5 are heated, by which the extruded flat tube 4 and the fin 5 are brazed, and furthermore, a mixed diffusion layer 8 of silicon and zinc is formed on the surface of the extruded flat tube 4.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an aluminum heat exchanger core and a method for producing the same, and more particularly, to a brazing composition comprising, for example, a flat aluminum heat exchange tube and aluminum fins. And a method for manufacturing the same.

[0002]

2. Description of the Related Art In general, an aluminum heat exchanger in which an aluminum or aluminum alloy (hereinafter referred to as aluminum) heat exchange tube and an aluminum fin are brazed is widely used. In order to improve the exchange efficiency, an extruded flat tube in which a heat exchange tube is formed of an extruded aluminum member is used.

[0003] In order to impart corrosion resistance (corrosion resistance) to a heat exchanger constructed as described above, generally, zinc (Zn) is adhered to the surface of a flat heat exchange tube, and the flat heat exchange tube is heated by additional heat of brazing. A Zn diffusion layer is provided by diffusing Zn on the surface of the tube. Further, a brazing sheet such as a brazing material containing zinc, that is, a clad material of a brazing composition is used for the fins.

[0004]

However, since the brazing sheet is used as the fin material, the cost is increased as compared with the cloth fin material in which the brazing material is not clad, and the brazing material is clad on the surface. In addition, the fin forming rolls are severely worn, so that the fin forming rolls need to be polished frequently, and burrs and the like are liable to be generated during the forming process of the louver or the like, so that there is a problem that the quality is deteriorated.

In order to improve the corrosion resistance of the flat heat exchange tube, Zn is previously deposited on the flat tube surface by a zincate method or a zinc (Zn) spraying method, and a Zn diffusion layer is formed during brazing to form a sacrificial electrode. However, this method has a problem that much time and effort are required for Zn deposition.

On the other hand, as a method of using a cloth fin material on which a brazing material is not clad, there is also known a method of applying an Al-Si alloy powder using aluminum (Al) and silicon (Si) to a flat tube and brazing the flat tube. However, in this method, the applied amount of the Al-Si alloy powder is extremely large, and there is a problem in terms of cost and assembly. A method using an electric resistance welded pipe clad with a brazing material in a flat pipe is also known,
In this method, since it is necessary to insert an insert into the inside in order to form a perforated tube, there is a problem that many steps are required and the production cost and the material cost increase.

The present invention has been made in view of the above circumstances, and uses a heat exchange tube to which Zn is not required to be attached in advance and a fin material which is not clad with a brazing composition, and has a corrosion resistance equal to or higher than that of the conventional one. It is another object of the present invention to provide a heat exchanger core having brazing properties and a method for manufacturing the same.

[0008]

In order to achieve the above object, according to the first aspect of the present invention, a copper element is contained in an amount of 0.01% or more.
An aluminum heat exchanger core obtained by brazing an aluminum heat exchange tube containing 0.6% or less and substantially consisting of aluminum and aluminum fins via a brazing composition. A mixed diffusion layer of silicon and zinc is formed on the surface of the heat exchange tube, and the fin is formed of a zinc-containing aluminum member for forming the zinc diffusion layer.

According to a third aspect of the present invention, there is provided an aluminum heat exchange tube and an aluminum fin containing 0.01% to 0.6% of copper element and substantially consisting of aluminum. A method for producing an aluminum heat exchanger core obtained by brazing through a coating composition,
A brazing composition comprising silicon and a fluorine-based flux is applied to the surface of the heat exchange tube, and the heat exchange tube and the fin are heated to a predetermined temperature using an aluminum member containing zinc for the fin. Then, the heat exchange tube and the fins are brazed, and a mixed diffusion layer of silicon and zinc is formed on the surface of the heat exchange tube. in this case,
The concentration of the mixed diffusion layer of silicon and zinc formed on the heat exchanger surface is 0.5 to 1.5% for silicon and 0.4 to 3.0% for zinc.

In the present invention, the shape of the heat exchange tube is arbitrary as long as it is an aluminum tube containing 0.01% or more and 0.6% or less of copper element and substantially consisting of aluminum. Preferably, it is preferably an extruded flat aluminum tube having a plurality of heat medium passages.
Further, it is preferable that the zinc concentration in the fin is 1 to 5% (claim 2).

According to the present invention, by using silicon and a fluorine-based flux for the brazing composition, it is not necessary to previously attach Zn to the heat exchange tube, and the fin is coated with the brazing composition. Not containing Zn-containing material fin material can be used, and at the time of brazing, a part of the fin is melted by the brazing composition and zinc in the fin is diffused to the surface, and the surface of the heat exchange tube contains silicon and zinc. A mixed diffusion layer is formed.

Therefore, a zinc diffusion layer can be formed on the surface of the heat exchange tube without depositing zinc on the surface of the heat exchange tube in advance. By being added within the range of 01% or more and 0.6% or less, the pitting potential between the fin and the fin can be set within an appropriate range, and heat exchange with good corrosion resistance and brazing property can be easily performed. A vessel core can be provided. Also, since there is no need to clad the brazing composition on the fins,
Since the processing of the fins becomes easy and the occurrence of burrs and the like can be prevented, a high-quality heat exchanger core can be provided. Further, the productivity can be improved and the cost can be reduced.

[0013]

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 is a perspective view showing a main part of an aluminum heat exchanger using an aluminum heat exchanger core according to the present invention.

The heat exchanger comprises a pair of opposed header tubes 3 having an inlet 1 or an outlet 2 for a heat medium and a plurality of extrusion tubes as heat exchange tubes arranged in parallel with each other and communicating with the header tubes 3. It is composed of a flat tube 4 and fins, for example, corrugated fins 5 disposed between the extruded flat tubes 4.
In the heat exchanger configured as described above, the header tube 3 and the extruded flat tube 4 are formed from an extruded aluminum member,
The corrugated fin 5 is formed by bending an aluminum plate material in a meandering shape, and the header tube 3, the extruded flat tube 4, and the corrugated fin 5 are integrally brazed via a brazing composition (brazing material). A heat exchanger is configured.

In this case, the heat exchanger core 6 composed of the extruded flat tubes 4 and the corrugated fins 5 is made of zinc (Z
n) Extruded flat aluminum tube without adhesion (for example, J
ISA1050), specifically, copper (Cu) element of 0.0
The corrugated fins 5 are formed of extruded flat tubes containing 1% or more and 0.6% or less and substantially made of aluminum, and the corrugated fins 5 are formed of a Zn-containing aluminum plate material that does not clad the brazing material. . Further, as the brazing composition, a mixture of silicon (Si) powder and fluorine-based flux powder, or a mixture of Si powder and Zn powder and fluorine-based flux powder is used. As the fluorine-based flux, for example, KAlF4, K2AlF5
A composition such as H2O or K3AlF6 is used. Such a fluorine-based flux is suitable because it does not corrode aluminum like a chloride. Further, the ratio (% by weight) of Si and the flux is Si: flux = 1: 2.

In order to manufacture the heat exchanger core 6, first, as shown in FIG. 2, an extruded flat aluminum tube 4 having a plurality of heat medium passages 4a and a Zn-containing bent bent meandering. Is prepared. On this occasion,
The corrugated fins 5 are formed by bending a Zn-containing aluminum plate material (for example, JIS A3N03, A3N23) in a meandering shape using a forming roll, so that abrasion of the forming roll is less than that of a brazing sheet clad with a brazing material. Further, even when a louver or the like is formed on the fin, no burrs or the like are generated, so that the quality of the fin can be improved.

Next, as shown in FIG. 3, a brazing composition 7 is applied to the surface of the extruded flat tube 4 using a binder such as a thermoplastic acrylic resin. In order to apply the brazing composition to the extruded flat tube 4, for example, a mixed slurry liquid of a binder and a brazing composition is applied by spraying, or a mixed slurry liquid of a binder and a brazing composition is applied. The extruded flat tube 4 is immersed therein and vertically lifted to remove excessively attached slurry liquid.

Next, the extruded flat tube 4 to which the brazing composition is attached and the Zn-containing corrugated fin 5 are assembled and fixed with a jig (not shown) or fixed to the header tube 3. Then, the extruded flat tube 4 and the corrugated fin 5 are integrally brazed by heating to a predetermined temperature, for example, 590 ° C. or higher in a heating furnace or the like to melt the brazing composition. At this time, a part of the corrugated fin 5 is melted by the brazing composition, Zn in the corrugated fin 5 diffuses to the surface of the extruded flat tube 4, and Si of the extruded flat tube 4 is formed together with Si in the brazing composition. A diffusion layer 8 of Si and Zn is formed on the surface. The extruded flat tube 4 and the corrugated fin 5 are A
They are integrally joined by a fillet 9 of an l-Si-Zn alloy. Therefore, since the diffusion layer 8 of Si and Zn is formed on the surface of the extruded flat tube 4, the heat exchanger core 6 has corrosion resistance.

[0019]

Next, an experiment for evaluating the brazeability and corrosion resistance of the heat exchanger core according to the present invention and a conventional aluminum heat exchanger core will be described.

Experiment-1 ◎ Materials used ★ Extruded flat tube Material: JIS A1050 (Cu content 0.02%): JIS A1050 + Zn spraying (Zn basis weight 8 g / m ² ): NE alloy (corrosion resistant alloy) (Composition: 0) (0.05% Si, 0.18% Fe, 0.4% Cu, 0.02% Zn, 0.04% Zr) Shape: External dimensions (width x thickness) = 19.2mm x 1.93mm (one side thickness) Thickness: 0.4 mm) ★ Fin: Material: Fabric material (JIS A3N03 + Zn content: 0% to 4.0%): Brazing sheet (A4343 + 1.0% Zn / 3N03 + 1.5% Zn / A4343 + 1.0% Zn): Shape (width × thickness) = 21.1 mm × 0.1 mm ★ Brazing composition Si powder + fluorine flux powder + binder Total adhesion amount: 16 g / m ² ◎ Brazing condition Current operating condition: Nitrogen atmosphere (Nitrogen Elementary amount: 40 m ³ / H): Temperature rise rate: 30 ° C./M

As shown in Table 1, the extruded flat tube 4 and the dough fin material (Zn content: 0% to 4.0%) were joined by brazing with the brazing composition. 1 to
4. In addition, when the joint between the extruded flat tube and the fin was cut and confirmed by the comparative brazing methods 1 and 2 (current brazing) in which the brazing was performed using brazing sheet fins, the brazing results shown in Table 2 were obtained. Was done.

In addition, brazing products are subjected to CASS test (JIS
H8681), the corrosion resistance was evaluated.
The result as shown in FIG.

When the cross section of the extruded flat tube 4 was examined for the diffusion of Zn and Si with an X-ray microanalyzer (XMA), the results shown in Table 2 were obtained.

[0024]

[Table 1]

[0025]

[Table 2]

As a result of the above experiment, the joining state of Examples 1 to 4 was not inferior to the heat exchanger core using the current brazing sheet, and the brazing rate was 99.5% or more.

When the corrosion resistance of the brazed product was examined by the CASS test, in Comparative Examples 1 and 2 and the current brazing methods 1 and 2, a through-hole was generated in a test time of 1500 hours. No. 4 products did not have through holes.

Further, Zn and Si on the surface of the extruded flat tube 4 are
As a result of examining the diffusion state (surface concentration, diffusion depth) of Zn, the Zn diffusion states of Examples 1 to 4 were 0.6% to 2.2%,
μm to 80 μm, Si diffusion state is 0.8% to 1.0
%, 67 μm to 78 μm.

As described above, using a brazing composition comprising a mixture of Si powder and a fluorine-based flux, an aluminum fin having a Zn content of 1.2% to 4.0%,
It has been found that a heat exchanger core obtained by brazing an aluminum extruded flat tube to which n does not adhere has brazing properties and corrosion resistance equivalent to or higher than those of a current heat exchanger core. Although not described in the above experimental results, when the Zn content of the fin material is less than 1%, the Zn diffusion concentration on the surface becomes 0.4% or less, and the sacrificial anode function of the Zn diffusion layer becomes insufficient. . On the other hand, if the Zn content exceeds 5%, the corrosion of the fin material itself becomes remarkable, shortening the life as a heat exchanger, lowering the material strength at high temperatures, and easily buckling the fin during brazing. Therefore, when the Zn content of the fin material is in the range of 1.0% to 5.0%, brazing properties and corrosion resistance equal to or higher than the current heat exchanger core can be obtained.

Although not shown in the above experimental results, the series of experimental results show that the larger the amount of Zn added,
A high-concentration Zn diffusion layer can be formed, and the corrosion resistance can be improved. In addition, since the Si diffusion layer makes the pitting potential on the extruded flat tube side noble, the corrosion resistance is higher than that of the extruded flat tube without the Si diffusion layer. It was found that improvement could be achieved.

Experiment-2 ◎ Material used Extruded flat tube Material: 1000 series aluminum alloy with different Cu content shown in Table 3 Shape: External dimensions (width x wall thickness) = 19.2 mm x 1.93
mm (one side thickness: 0.4mm)

[0032]

[Table 3] ★ Fin material: JIS A3N23 (Zn content 2.0%) Shape: (width × thickness) = 21.1 mm × 0.1 mm ★ Brazing composition Si powder + fluorine flux powder + binder Total adhesion amount: 16 g / m ² ◎ Brazing conditions Current operating conditions: In a nitrogen atmosphere (nitrogen amount: 40 m ³ / H): Heating rate: 30 ° C./M

When the joint between the extruded flat tube and the fin brazed with the above brazing composition was cut and the joining state was confirmed, the brazing ratio was 99.5% or more in all cases.
In addition, as a result of examining the diffusion state (surface concentration, diffusion depth) of Zn and Si in the extruded flat tube between the fins by an X-ray microanalyzer, the surface concentration of Zn was 0.9 to 1.1 in all cases.
%, The diffusion depth is 71 to 78 μm, and the surface concentration of Si is 0.1%.
9 to 1.2%, the diffusion depth was in the range of 66 to 77 μm.

Next, in order to evaluate the corrosion resistance, the potential difference between the inside of the extruded flat tube (about 150 μm inside from the surface) and the fin was measured (the pitting potential anodically polarized in a 4.82% AlCl ₃ .6H ₂ O solution). And CA for brazing products
When the SS test was performed, the results shown in Table 4 were obtained.

[0035]

[Table 4]

As a result of the above experiment, in Comparative Example 1 in which the Cu content of the extruded flat tube was 0.005%, the potential difference from the fin was 38
mV, and a through hole was generated between the fins after 1500 hours in the CASS test. In Comparative Example 2 in which the Cu content was 0.071%, since the potential difference from the fin was sufficient, the corrosion between the fins was slight. A through hole was formed near the pipe. In contrast, Embodiments 2 and 3 of the present invention
Since the potential difference from the fin is 85 mV or more and the Cu content of the extruded flat tube is as small as 0.18% or less, CA
Even in the SS test for 1500 hours, the corrosion between the fins and the vicinity of the header tube were all slight. In Example 1 in which the potential difference from the fin was 63 mV, the Cu content was 0.5
5% of Example 4 has a CASS test 150 near the header tube.
At 0 hours, corrosion holes of 200 to 250 μm were found, but no through holes were formed. Although not specified, C
In the case where the u content is 0.1% or 0.6%, Example 1 (C
u content 0.13%), Example 4 (Cu content 0.55
%) Is expected to be obtained.

[0037]

As described above, according to the present invention, by using silicon and a fluorine-based flux for the brazing composition, it is not necessary to previously attach Zn to the heat exchange tube, and the fins can be used. A finned material containing Zn, which is not clad with a brazing composition, can be used. At the time of brazing, a part of the fins is melted by the brazing composition, and zinc in the fins is removed from the surface of the heat exchange tube. To form a mixed diffusion layer of silicon and zinc on the surface of the heat exchange tube.

Therefore, a zinc diffusion layer can be formed on the surface of the heat exchange tube without previously depositing zinc on the surface of the heat exchange tube.
% And not more than 0.6% and substantially made of aluminum, so that the pitting potential between the fin and the fin can be kept within an appropriate range, and the heat exchanger easily has good corrosion resistance and brazing properties. A core can be provided. In addition, since it is not necessary to clad the brazing composition on the fins, the fins can be easily processed and the occurrence of burrs and the like can be prevented, so that a high-quality heat exchanger core is provided. be able to. Furthermore, while improving productivity,
Excellent effects such as low cost can be obtained.

[Brief description of the drawings]

FIG. 1 is a perspective view of a main part showing an example of a heat exchanger using a heat exchanger core according to the present invention.

FIG. 2 is a perspective view showing an extruded flat tube and a corrugated fin according to the present invention.

FIG. 3 is a cross-sectional view showing an example of a state in which a brazing composition is applied to an extruded flat tube according to the present invention.

FIG. 4 is an enlarged sectional view showing a brazed state of a heat exchange tube and a fin according to the present invention.

[Explanation of symbols]

 Reference Signs List 4 extruded flat tube (heat exchange tube) 5 corrugated fin 6 heat exchanger core 7 brazing composition 8 Si, Zn diffusion layer

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Toshihiro Suzuki 161 Kambara, Kambara-cho, Anbara-gun, Shizuoka Nippon Light Metal Co., Ltd. Inside the Kambara Heat Exchange Products Factory (72) Inventor Yoshihiko Tanaka 161 Kambara, Kambara-cho, Anbara-gun, Shizuoka Japan Nippon Light Metal (72) Inventor Akinori Ogasawara 2-2-2-20 Higashishinagawa, Shinagawa-ku, Tokyo Inside Japan Light Metal Co., Ltd.

Claims (3)

[Claims] An aluminum heat exchange tube containing 0.01% or more and 0.6% or less of copper element and substantially made of aluminum and a fin made of aluminum via a brazing composition. An aluminum heat exchanger core formed by brazing, wherein a mixed diffusion layer of silicon and zinc is formed on the surface of the heat exchange tube, and the fin is aluminum containing zinc for forming the zinc diffusion layer. An aluminum heat exchanger core characterized by being formed by a member made of aluminum. 2. The aluminum heat exchanger core according to claim 1, wherein the zinc concentration in the fin is 1 to 5%. 3. A brazing composition comprising an aluminum heat exchange tube and aluminum fins containing 0.01% or more and 0.6% or less of copper element and substantially consisting of aluminum and having a balance of aluminum. A method for manufacturing an aluminum heat exchanger core, comprising: applying a brazing composition comprising silicon and a fluorine-based flux to the surface of the heat exchange tube; Using a member, heating the heat exchange tube and the fin to a predetermined temperature, brazing the heat exchange tube and the fin, and forming a mixed diffusion layer of silicon and zinc on the surface of the heat exchange tube. A method for producing an aluminum heat exchanger core, comprising: