JPWO2020161817A1 - Manufacturing method of corrosion resistance diagnostic parts and diagnostic method - Google Patents

Abstract

The corrosion resistance diagnostic component according to the present invention is a corrosion resistance diagnostic component used for diagnosing the corrosion status of a material to be diagnosed in which a sacrificial layer containing zinc is formed on the surface of a core material containing aluminum. A first core material containing aluminum and a first sacrificial layer containing zinc, which is formed on the surface of the first core material and has lower corrosion resistance than the first core material, are provided. At a position adjacent to the first sacrificial layer, the surface of the first sacrificial layer is removed from the boundary between the first sacrificial layer and the first core material to the inside of the first core material, and the first core material is removed. The structure is such that an exposed portion with an exposed core material is formed.

Description

The present invention relates to a corrosion resistance diagnostic component used for diagnosing the corrosion status of a material to be diagnosed in which a sacrificial layer containing zinc is formed on the surface of a core material containing aluminum, a corrosion resistance diagnostic device provided with the corrosion resistance diagnostic component, and the corrosion resistance diagnosis. The present invention relates to a heat exchanger provided with parts, an air conditioner provided with the corrosion resistance diagnostic parts, a method for manufacturing the corrosion resistance diagnostic parts, and a diagnostic method using the corrosion resistance diagnostic parts.

Conventionally, there are products using a material in which a sacrificial layer containing zinc is formed on the surface of a core material containing aluminum. For example, in a heat exchanger of an air conditioner, a heat transfer tube in which a sacrificial layer containing zinc is formed on the surface of a core material containing aluminum may be used. Hereinafter, a heat transfer tube in which a sacrificial layer containing zinc is formed on the surface of a core material containing aluminum may be simply referred to as an aluminum heat transfer tube. There is a concern that the aluminum heat transfer tube may be locally corroded to form a through hole in the aluminum heat transfer tube, resulting in refrigerant leakage. Therefore, there is a demand for a technique for detecting corrosion that leads to refrigerant leakage by grasping the progress of corrosion of the aluminum heat transfer tube.

Therefore, for example, Patent Document 1 discloses a technique for diagnosing the life of a heat exchanger using an aluminum heat transfer tube by using a corrosion-resistant life diagnosis component. Specifically, the corrosion resistant life diagnostic component comprises a plate-like base material having an aluminum layer on its surface. Then, in the corrosion resistance life diagnostic component, a sacrificial anode layer made of a zinc-aluminum alloy is formed on a part of the surface of the base material. That is, the corrosion-resistant life diagnostic component has a base material exposed portion on which the base material is exposed is formed on a part of the surface. Then, by observing the exposed part of the base material of the corrosion resistance life diagnosis part, when a local corrosion mark appears within a specified distance from the place where the sacrificial anode layer was formed at the beginning of manufacturing, heat using an aluminum heat transfer tube is used. It is diagnosed that the exchanger has reached the end of its life.

Japanese Patent No. 6058154

The corrosion-resistant life diagnostic component described in Patent Document 1 is a zinc-aluminum alloy on the surface of the base material by spraying zinc on the surface of the base material or applying a zinc-containing paint on the surface of the base material. Form a sacrificial anode layer. When forming this sacrificial anode layer, zinc diffuses to the base metal side. That is, in the corrosion-resistant life diagnosis component described in Patent Document 1, when the sacrificial anode layer is formed, diffused zinc is present in at least a part of the base material exposed portion observed at the time of life diagnosis. For this reason, in the corrosion-resistant life diagnostic component described in Patent Document 1, local corrosion is suppressed by zinc existing in the exposed portion of the base material, and the diagnostic accuracy of the corrosion state of the heat exchanger using the aluminum heat transfer tube is lowered. There was a problem that it would end up.

The present invention has been made to solve the above-mentioned problems, and it is possible to more accurately diagnose the corrosion state of the material to be diagnosed in which a sacrificial layer containing zinc is formed on the surface of a core material containing aluminum. The first purpose is to obtain a possible corrosion resistance diagnostic component. Further, the present invention relates to a corrosion resistance diagnostic device provided with the corrosion resistance diagnostic component, a heat exchanger provided with the corrosion resistance diagnostic component, an air conditioner provided with the corrosion resistance diagnostic component, a method for manufacturing the corrosion resistance diagnostic component, and the corrosion resistance. A second object is to provide a diagnostic method using a diagnostic component.

The corrosion resistance diagnostic component according to the present invention is a corrosion resistance diagnostic component used for diagnosing the corrosion status of a material to be diagnosed in which a sacrificial layer containing zinc is formed on the surface of a core material containing aluminum. A first core material containing aluminum and a first sacrificial layer containing zinc formed on the surface of the first core material and having a lower corrosion resistance than the first core material are provided, and the corrosion resistance diagnostic component includes the above-mentioned At a position adjacent to the first sacrificial layer, the surface of the first sacrificial layer is removed from the boundary between the first sacrificial layer and the first core material to the inside of the first core material, and the first The structure is such that an exposed portion with an exposed core material is formed.

Further, the corrosion resistance diagnostic device according to the present invention is based on the corrosion resistance diagnostic component according to the present invention, the photographing portion for photographing the surface of the exposed portion, and the image data photographed by the photographing portion to corrode the surface of the exposed portion. It is equipped with a detection unit that detects the situation.

Further, the heat exchanger according to the present invention includes the corrosion resistance diagnostic component according to the present invention and a refrigerant pipe in which a sacrificial layer containing zinc is formed on the surface of a core material containing aluminum and a refrigerant flows, and the corrosion resistance diagnosis is performed. The parts are made of the same members as the refrigerant pipe.

Further, the air conditioner according to the present invention includes a corrosion resistance diagnostic component according to the present invention, a heat exchanger having a heat transfer tube having a sacrificial layer containing zinc formed on the surface of a core material containing aluminum, and a core containing aluminum. A sacrificial layer containing zinc is formed on the surface of the material, and the refrigerant pipe is provided with a refrigerant flowing into the heat exchanger or a refrigerant flowing out of the heat exchanger, and the corrosion resistance diagnostic component is the same as the refrigerant pipe. It is made of members.

Further, the method for manufacturing a corrosion resistance diagnostic component according to the present invention includes a preparatory step of preparing a material for a corrosion resistance diagnostic component in which the first sacrificial layer is formed on the surface of the first core material, and a surface of the first sacrificial layer. To the inner side of the first core material from the boundary between the first sacrificial layer and the first core material, and forming the exposed portion at a position adjacent to the first sacrificial layer. I have.

Further, the diagnostic method according to the present invention is a diagnostic method for diagnosing the corrosion state of the material to be diagnosed in which a sacrificial layer containing zinc is formed on the surface of a core material containing aluminum by using the corrosion resistance diagnostic component according to the present invention. Therefore, on the surface of the exposed portion, a range within a specified distance from the first sacrificial layer is set as the first range, and when a local corrosion mark appears in the first range, the material to be diagnosed is used. Diagnose the product at the end of its life.

In the corrosion resistance diagnostic component according to the present invention, the exposed portion is removed from the surface of the first sacrificial layer to the inner side of the first core material from the boundary between the first sacrificial layer and the first core material, and the first The core material is exposed. That is, in the exposed portion of the corrosion resistance diagnostic component according to the present invention, the boundary portion between the first sacrificial layer and the first core material is completely removed. In other words, in the exposed portion of the corrosion resistance diagnostic component according to the present invention, zinc diffused in the first core material during the formation of the first sacrificial layer is completely removed. Therefore, in the corrosion resistance diagnostic component according to the present invention, the corrosion status of the material to be diagnosed can be diagnosed more accurately than before based on the corrosion status of the surface of the exposed portion.

It is a refrigerant circuit diagram which shows the schematic structure of the air conditioner which concerns on Embodiment 1 of this invention. It is a functional block diagram of the corrosion resistance diagnostic apparatus which concerns on Embodiment 1 of this invention. It is a top view which shows the outline of the corrosion resistance diagnostic part which concerns on Embodiment 1 of this invention. It is a vertical cross-sectional view which shows the outline of the corrosion resistance diagnostic part which concerns on Embodiment 1 of this invention. It is a model figure for demonstrating the reaction which occurs at the time of corrosion progress of the corrosion resistance diagnostic part which concerns on Embodiment 1 of this invention. It is a figure which shows the change process of the exposed part of the corrosion resistance diagnostic part which concerns on Embodiment 1 of this invention. It is a vertical cross-sectional view of the corrosion resistance diagnosis component which concerns on Embodiment 1, and is the figure which shows the state in which the first sacrificial layer of the corrosion resistance diagnosis component is totally corroded. It is a figure which shows the change process of the surface of the 1st sacrificial layer of the corrosion resistance diagnostic part which concerns on Embodiment 1 of this invention. It is a flowchart which shows the manufacturing process of the corrosion resistance diagnostic part which concerns on Embodiment 1 of this invention. It is a figure which shows the process of forming the exposed part of the corrosion resistance diagnostic part which concerns on Embodiment 1 of this invention. It is a flowchart which shows the composite cycle test performed in Embodiment 1 of this invention. It is a side view which shows a part of the core part of the outdoor heat exchanger which concerns on Embodiment 4 of this invention.

An example of the present invention will be described in each of the following embodiments with reference to drawings and the like. The form of each configuration described in the following embodiments is merely an example. The present invention is not limited to the configurations described in the following embodiments. Further, in each of the drawings below, the relationship between the sizes of the constituent members may differ from the actual product in which the present invention is carried out.

Embodiment 1.
[Structure of corrosion resistance diagnostic parts, configuration of corrosion resistance diagnostic device, and purpose of providing these]
In the air conditioner 200 according to the first embodiment, a heat transfer tube made of a material containing aluminum is used as the heat transfer tube of the outdoor heat exchanger 100. This heat transfer tube has a structure in which a sacrificial layer containing zinc is formed on the surface thereof to suppress corrosion of the heat transfer tube. That is, the heat transfer tube of the outdoor heat exchanger 100 has a structure in which a sacrificial layer containing zinc is formed on the surface of a core material containing aluminum. In the following, the sacrificial layer containing zinc may be referred to as a zinc sacrificial layer. Further, in the following, a member in which a zinc sacrificial layer is formed on the surface of a core material containing aluminum may be referred to as an aluminum material with a zinc sacrificial layer. Further, in the following, a heat transfer tube using a core material containing aluminum may be referred to as an aluminum heat transfer tube. Here, in the first embodiment, the core material of the aluminum heat transfer tube of the outdoor heat exchanger 100 is an aluminum alloy containing no zinc. The aluminum alloy is, for example, an aluminum-manganese alloy. Further, the zinc sacrificial layer of the heat transfer tube of the outdoor heat exchanger 100 is an aluminum-zinc alloy layer.

The zinc sacrificial layer is potentially lower than the core aluminum alloy. Therefore, in the heat transfer tube of the outdoor heat exchanger 100, the sacrificial layer is preferentially corroded, and the corrosion of the aluminum alloy of the core material can be suppressed. As will be described later, the corrosion form of the zinc sacrificial layer is total corrosion in which the surface layer is uniformly corroded from the surface side to the inner side. Further, the corrosion form of the core material which is an aluminum alloy is local corrosion. Therefore, by forming a sacrificial layer containing zinc on the surface of the aluminum heat transfer tube of the outdoor heat exchanger 100, the corrosion resistance of the aluminum heat transfer tube of the outdoor heat exchanger 100 can be improved.

In an aluminum heat transfer tube in which the surface of the core material is covered with a zinc sacrificial layer, the zinc sacrificial layer may be peeled off at a part of the surface of the core material. Further, in an aluminum heat transfer tube in which the surface of the core material is covered with a zinc sacrificial layer, the aluminum alloy as the core material may be exposed on a part of the surface from the beginning of production. As described above, the portion where the aluminum alloy as the core material is exposed on the surface of the aluminum heat transfer tube is also protected by the above-mentioned preferential corrosion of the zinc sacrificial layer. That is, the corrosion resistance of the aluminum heat transfer tube whose core material is covered with the zinc sacrificial layer greatly affects the product life of the outdoor heat exchanger 100 and the outdoor unit equipped with the outdoor heat exchanger 100. The corrosion resistance diagnostic component and the corrosion resistance diagnostic device according to the first embodiment are used for the purpose of diagnosing the corrosion state of the aluminum heat transfer tube whose surface is covered with the zinc sacrificial layer. In other words, the corrosion resistance diagnostic component and the corrosion resistance diagnostic device according to the first embodiment are the outdoor heat exchanger 100 and the outdoor heat exchanger 100 using an aluminum heat transfer tube whose core material surface is covered with a zinc sacrificial layer. It is used for the purpose of grasping the life of the installed outdoor unit. That is, in the first embodiment, the aluminum heat transfer tube whose surface is covered with the zinc sacrificial layer is the material to be diagnosed.

FIG. 1 is a refrigerant circuit diagram showing a schematic configuration of an air conditioner according to a first embodiment of the present invention. As shown in FIG. 1, the air conditioner 200 includes a compressor 201, a muffler 202, a four-way valve 203, an outdoor heat exchanger 100, a capillary tube 205, a strainer 206, an electronically controlled expansion valve 207, and the like. A refrigerant circuit is provided in which a stop valve 208a, an indoor heat exchanger 209, a stop valve 208b, and an auxiliary muffler 210 are connected by a refrigerant pipe 204.

The indoor unit having the indoor heat exchanger 209 of the air conditioner 200 controls the actuators such as the compressor 201 and the electronically controlled expansion valve 207 based on the temperatures of the outside air, the indoor air, the refrigerant, and the like. The device 211 is provided. The four-way valve 203 is a valve that switches between cooling and heating refrigeration cycles, and is controlled by the control device 211. As will be described later, the control device 211 also functions as a control device for the corrosion resistance diagnostic device 300. Of course, the control device of the air conditioner 200 and the control device of the corrosion resistance diagnostic device 300 may be configured separately.

The control device 211 is composed of dedicated hardware or a CPU (Central Processing Unit) that executes a program stored in a memory. The CPU is also referred to as a central processing unit, a processing unit, an arithmetic unit, a microprocessor, a microcomputer, or a processor.

When the control device 211 is dedicated hardware, the control device 211 may be, for example, a single circuit, a composite circuit, an ASIC (Application Specific Integrated Circuit), an FPGA (Field-Programmable Gate Array), or a combination thereof. Applicable. Each of the functional units realized by the control device 211 may be realized by individual hardware, or each functional unit may be realized by one hardware.

When the control device 211 is a CPU, each function executed by the control device 211 is realized by software, firmware, or a combination of software and firmware. Software and firmware are written as programs and stored in memory. The CPU realizes each function of the control device 211 by reading and executing the program stored in the memory. Here, the memory is a non-volatile or volatile semiconductor memory such as RAM, ROM, flash memory, EPROM, or EEPROM.

Some of the functions of the control device 211 may be realized by dedicated hardware, and some may be realized by software or firmware.

Next, an operation example of the air conditioner 200 during the cooling operation will be described with reference to FIG. When the four-way valve 203 is switched to the flow path during the cooling operation by the control device 211, the refrigerant is compressed by the compressor 201 to become a high-temperature and high-pressure gas refrigerant, and the outdoor heat exchanger 100 is supplied via the four-way valve 203. Inflow. The high-temperature and high-pressure gas refrigerant that has flowed into the outdoor heat exchanger 100 exchanges heat with the outdoor air that passes through the outdoor heat exchanger 100, and flows out as a high-pressure liquid refrigerant. The high-pressure liquid refrigerant flowing out of the outdoor heat exchanger 100 is depressurized by the capillary tube 205 and the electronically controlled expansion valve 207, becomes a low-pressure gas-liquid two-phase refrigerant, and flows into the indoor heat exchanger 209. The gas-liquid two-phase refrigerant that has flowed into the indoor heat exchanger 209 exchanges heat with the indoor air that passes through the indoor heat exchanger 209, cools the indoor air, becomes a low-temperature low-pressure gas refrigerant, and is sucked into the compressor 201. Will be done.

Next, an operation example of the air conditioner 200 during the heating operation will be described with reference to FIG. When the four-way valve 203 is switched to the flow path for heating operation by the control device 211, the refrigerant is compressed by the compressor 201 to become a high-temperature and high-pressure gas refrigerant in the same manner as described above, and becomes indoor heat through the four-way valve 203. It flows into the exchanger 209. The high-temperature and high-pressure gas refrigerant flowing into the indoor heat exchanger 209 exchanges heat with the indoor air passing through the indoor heat exchanger 209, warms the indoor air and becomes a high-pressure liquid refrigerant. The high-pressure liquid refrigerant flowing out of the indoor heat exchanger 209 is depressurized by the electronically controlled expansion valve 207 and the capillary tube 205 to become a low-pressure gas-liquid two-phase refrigerant, which flows into the outdoor heat exchanger 100. The low-pressure gas-liquid two-phase refrigerant that has flowed into the outdoor heat exchanger 100 exchanges heat with the outdoor air that passes through the outdoor heat exchanger 100, becomes a low-temperature low-pressure gas refrigerant, and is sucked into the compressor 201.

FIG. 2 is a functional block diagram of the corrosion resistance diagnostic device according to the first embodiment of the present invention.
The corrosion resistance diagnostic device 300 includes an imaging unit 312, a detection unit 313, a storage unit 314, a comparison unit 315, a notification unit 316, a control device 211, and a corrosion resistance diagnostic component 1 described later. The photographing unit 312 is, for example, a photographing device such as a digital camera or a television camera. Based on the control signal from the control device 211, the photographing unit 312 photographs the surface of the corrosion resistance diagnostic component 1 described later. More specifically, the photographing unit 312 photographs at least the surface of the exposed portion 3a described later of the corrosion resistance diagnostic component 1. The image data of the surface of the corrosion resistance diagnostic component 1 photographed by the photographing unit 312 is input to the detecting unit 313. The detection unit 313 obtains a digital image signal by A / D (Analog / Digital) conversion of the image data output from the photographing unit 312 based on the control signal from the control device 211, and obtains a digital image signal, and the corrosion resistance diagnostic component 1 Analyze the image data of the surface of. That is, the detection unit 313 detects the corrosion state of the surface of the exposed portion 3a of the corrosion resistance diagnostic component 1 from the image data photographed by the photographing unit 312.

The image data analyzed by the detection unit 313 is output to the comparison unit 315 and the storage unit 314. The storage unit 314 is, for example, a memory, and stores parameters indicating a corrosion state on the surface of the exposed portion 3a of the corrosion resistance diagnostic component 1. In the first embodiment, the storage unit 314 stores the image data output from the detection unit 313 as a parameter indicating the corrosion state of the surface of the exposed portion 3a of the corrosion resistance diagnostic component 1. The comparison unit 315 compares the detection result of the detection unit 313 with the parameters stored in the storage unit 314. In the case of the first embodiment, the comparison unit 315 compares the image data sent from the detection unit 313 with the image data stored in the storage unit 314. The notification unit 316 notifies the comparison result of the comparison unit 315. In the first embodiment, an operation panel or an operation panel (not shown) of the air conditioner 200 is used as the notification unit 316. That is, in the first embodiment, the notification unit 316 notifies the comparison result of the comparison unit 315 in the form of displaying the comparison result of the comparison unit 315.

The detection unit 313 and the comparison unit 315 are composed of, for example, a CPU that executes a program stored in dedicated hardware or a memory, similarly to the control device 211. The detection unit 313 and the comparison unit 315 may be a part of the functional unit of the control device 211, or may be configured separately from the control device 211. Further, for example, the detection unit 313 can be configured as hardware in combination with the photographing unit 312. The hardware in which the photographing unit 312 and the detecting unit 313 are combined is, for example, a line scan camera, a three-dimensional image processing system, an image discrimination sensor, or the like.

The corrosion resistance diagnostic device 300 configured in this way is mounted on the above-mentioned air conditioner 200. The corrosion resistance diagnostic device 300 may be sold together with the air conditioner 200, or may be sold together with the outdoor heat exchanger 100. That is, the corrosion resistance diagnostic device 300 may be treated as a configuration of the air conditioner 200, or may be treated as a configuration of the outdoor heat exchanger 100.

[Aluminum material with zinc sacrificial layer used for aluminum heat transfer tube]
When manufacturing an aluminum material with a zinc sacrificial layer used for an aluminum heat transfer tube, first, a core material using a material containing aluminum is prepared. Then, by forming a zinc sacrificial layer having a lower corrosion resistance than the core material on the surface of the core material, an aluminum material with a zinc sacrificial layer used for an aluminum heat transfer tube is manufactured. Specifically, for example, an aluminum alloy such as an aluminum-manganese alloy is used as a core material, a sacrificial layer of an aluminum-zinc alloy is formed on the surface of the core material, and an aluminum material with a zinc sacrificial layer used for an aluminum heat transfer tube is used. Is manufactured.

As the aluminum material with a zinc sacrificial layer, an aluminum clad material or a zinc sprayed aluminum material is used. The aluminum clad material is produced by rolling and heat-treating a material containing aluminum as a core material and an aluminum-zinc alloy material as a zinc sacrificial layer, and joining them together. Zinc sprayed aluminum material is produced by spraying metallic zinc on the surface of a core material containing aluminum and diffusing zinc into the core material by heat treatment.

When a circular tube is used as the heat transfer tube of the heat exchanger, both an aluminum clad material and a zinc sprayed aluminum material can be used.

On the other hand, a flat tube may be used as the heat transfer tube of the heat exchanger. The flat tube has a flat cross-sectional shape and has a pair of flat portions facing a part of the external shape. Further, a plurality of refrigerant flow paths are formed inside the flat pipe. The flat tube configured in this way is used, for example, as a fin tube type heat exchanger in which fin materials are combined. By using a flat tube for the heat transfer tube of the heat exchanger, there is an advantage that the area inside the tube in contact with the refrigerant can be increased and the ventilation resistance can be further reduced as compared with the heat exchanger using a circular tube. .. Since it is difficult to use an aluminum clad material for a flat tube due to its complicated shape, a zinc sprayed aluminum material is used.

When a heat transfer tube is composed of zinc-sprayed aluminum material, nozzles for spraying zinc are installed on both sides of a tubular member containing aluminum as a core material, and molten zinc is sprayed from these nozzles onto the surface of the tubular member. .. Therefore, on the surface of the tubular member, an unsprayed portion of zinc may be formed around a portion facing the direction perpendicular to the nozzle facing direction. That is, the core material of the heat transfer tube made of the zinc sprayed aluminum material may be exposed on a part of the surface. However, with respect to the portion where the core material is exposed on the surface, the zinc sacrificial layer around the portion exerts an anticorrosion function. Since the anticorrosion performance of the zinc sacrificial layer against the core material is determined by the amount of zinc to be sprayed and the degree of zinc diffusion due to heat treatment, the zinc sacrificial layer is designed according to the product life.

The corrosion resistance diagnostic component 1 provided in the corrosion resistance diagnostic device 300 according to the first embodiment is particularly effective in diagnosing the presence or absence of the anticorrosion function of the zinc sacrificial layer with respect to the portion where the core material is exposed on the surface. Therefore, in the first embodiment, a case where a zinc sprayed aluminum material is used as the aluminum heat transfer tube of the outdoor heat exchanger 100 will be described below as an example.

[Overview of corrosion resistance diagnostic parts]
FIG. 3 is a plan view showing an outline of the corrosion resistance diagnostic component according to the first embodiment of the present invention. FIG. 4 is a vertical cross-sectional view showing an outline of the corrosion resistance diagnostic component according to the first embodiment of the present invention.
Here, in order to distinguish between the core material of the corrosion resistance diagnostic component 1 and the core material of the material to be diagnosed, the core material of the corrosion resistance diagnostic component 1 will be referred to as the first core material 3. Further, in the following, in order to distinguish between the zinc sacrificial layer of the corrosion resistance diagnostic component 1 and the zinc sacrificial layer of the material to be diagnosed, the zinc sacrificial layer of the corrosion resistance diagnostic component 1 is referred to as a first sacrificial layer 2. In addition, in FIG. 3 and FIG. 4, the concentration of zinc in the first sacrificial layer 2 is shown by hatching. Therefore, in the cross-sectional view of FIG. 4, hatching of the cross-sectional portion is omitted. The denser the hatching, the higher the zinc concentration. The alternate long and short dash line shown in FIG. 4 indicates the boundary between the first sacrificial layer 2 and the first core material 3.

The corrosion resistance diagnostic component 1 is used for diagnosing the corrosion status of the material to be diagnosed. In the first embodiment, as the material of the corrosion resistance diagnostic component 1, an aluminum material with a zinc sacrificial layer used for the aluminum heat transfer tube of the outdoor heat exchanger 100, which is the material to be diagnosed, is used. This aluminum material with a zinc sacrificial layer is a zinc sprayed aluminum material. This zinc sprayed aluminum material heat-treats metallic zinc uniformly sprayed on the surface of the core material containing aluminum to diffuse the zinc into the core material. Due to this diffusion of zinc, a zinc sacrificial layer, which is an aluminum-zinc alloy, is formed on the surface of the core material. During the heat treatment, zinc diffuses from the surface layer of the core material toward the inside. Therefore, the zinc sacrificial layer is an aluminum-zinc alloy layer having a predetermined thickness having a concentration gradient in which the zinc concentration of the outermost layer is the highest and the concentration decreases toward the core material.

When the zinc sprayed aluminum material thus produced is used as the material for the corrosion resistance diagnostic component 1, the core material portion in which zinc is not diffused by the heat treatment becomes the first core material 3. Further, the portion where zinc is diffused becomes the first sacrificial layer 2. That is, the corrosion resistance diagnostic component 1 includes a first core material 3 containing aluminum and a first sacrificial layer 2 containing zinc, which is formed on the surface of the first core material 3 and has lower corrosion resistance than the first core material 3. It will be a prepared configuration.

Further, a part of the surface of the corrosion resistance diagnostic component 1 is removed by cutting or the like in the depth direction, and an exposed portion 3a is formed at a position adjacent to the first sacrificial layer 2. The exposed portion 3a is removed from the surface of the first sacrificial layer 2 to the inner side of the first core material 3 from the boundary between the first sacrificial layer 2 and the first core material 3, for example, by cutting, and the first core material 3 is removed. Is exposed. By forming the exposed portion 3a in this way, zinc is completely removed from the surface of the exposed portion 3a. That is, the portion of the corrosion resistance diagnostic component 1 where the first sacrificial layer 2 is formed is a state in which the first sacrificial layer 2 in which zinc is diffused and the first core material 3 in which zinc is not diffused are laminated. It has become. Further, the exposed portion 3a portion of the corrosion resistance diagnostic component 1 is in a state in which the first sacrificial layer 2 is not laminated on the first core material 3.

The corrosion resistance diagnostic component 1 is provided in the outdoor unit having the outdoor heat exchanger 100 together with the outdoor heat exchanger 100. For example, the corrosion resistance diagnostic component 1 is attached to the outdoor heat exchanger 100.

The corrosion resistance diagnostic component 1 may be sold together with the air conditioner 200, or may be sold together with the outdoor heat exchanger 100. That is, the corrosion resistance diagnostic component 1 may be treated as a configuration of the air conditioner 200 or may be treated as a configuration of the outdoor heat exchanger 100.

[Progress of corrosion in corrosion resistance diagnostic parts]
FIG. 5 is a model diagram for explaining the reaction that occurs during the progress of corrosion of the corrosion resistance diagnostic component according to the first embodiment of the present invention.
As described above, the corrosion resistance diagnostic component 1 according to the first embodiment uses the aluminum material with a zinc sacrificial layer used for the aluminum heat transfer tube of the outdoor heat exchanger 100. Therefore, FIG. 5 can be said to be a model diagram for explaining the reaction that occurs when the aluminum heat transfer tube of the outdoor heat exchanger 100 progresses to corrosion.

The corrosion resistance diagnostic component 1 can be seen as a configuration in which two metals having different potentials are electrically connected. Specifically, it can be seen that the first core material 3 which is an aluminum alloy such as an aluminum-manganese alloy and the first sacrificial layer 2 which is an aluminum-zinc alloy are electrically connected. Therefore, when the liquid junction 4 straddling the first core material 3 and the first sacrificial layer 2 is formed, the first sacrificial layer 2 which is an aluminum-zinc alloy is the first core material 3 which is an aluminum alloy. Since the potential is lower than that of, it functions as an anode through which the oxidation reaction proceeds. Further, when the liquid junction 4 straddling the first core material 3 and the first sacrificial layer 2 is formed, the first core material 3 which is an aluminum alloy is more than the first sacrificial layer 2 which is an aluminum-zinc alloy. Since the potential is high, it functions as a cathode where the reduction reaction proceeds.

Specifically, the oxidation reaction of the aluminum-zinc alloy represented by the formulas (1) and (2) proceeds on the anode side.
^{Al → Al 3+ + 3e - ···} (1)
^{Zn → Zn 2+ + 2e - ···} (2)

On the other hand, on the cathode side, the oxygen reduction reaction represented by the formulas (3) and (4) proceeds.
_{O 2 + 2H 2 O + 4e} - → 4OH - ··· (3)
_{^{2H + + 2e - → H 2}} ··· (4)

As shown in FIG. 5, the oxidation reaction represented by the formulas (1) and (2) and the reduction reaction represented by the formulas (3) and (4) proceed with the movement of electrons. These oxidation and reduction reactions proceed even if the surface of the first core material 3 which is an aluminum alloy is not covered with the first sacrificial layer 2 as long as the movement of electrons can reach it. On the other hand, in the region where the movement of electrons does not reach, the oxygen reduction reaction does not proceed, and the corrosion reaction of the first core material 3 alone proceeds. The range in which the movement of electrons reaches is called the "corrosion-proof range of the zinc sacrificial layer against the core material" or simply the "corrosion-proof range". This anticorrosion range has a great influence on the diagnosis of the product life of the corrosion resistance diagnostic component 1. The correlation between product life and anticorrosion range will be described later.

The first sacrificial layer 2 which is an aluminum-zinc alloy and the first core material 3 which is an aluminum alloy are characterized by their respective corrosion forms. Corrosion of the first sacrificial layer 2 which is a zinc sacrificial layer suppresses the corrosion of the first core material 3 which is within the corrosion protection range. On the other hand, corrosion of the first core material 3 outside the corrosion protection range progresses.

Corrosion that occurs in the first sacrificial layer 2, which is a zinc sacrificial layer, is caused by the addition of zinc to aluminum, which weakens the corrosion resistance of the surface corrosion-resistant passivation film, which is a feature of aluminum alloys, and causes total corrosion. Take the form. This total corrosion proceeds at a rate corresponding to the zinc concentration. Therefore, in the first sacrificial layer 2 in which the zinc concentration uniformly decreases from the surface to the inside, the entire surface corrosion proceeds uniformly from the surface at a predetermined speed in the depth direction. It is possible to grasp how much the total corrosion progresses in the depth direction in a predetermined time by observing the cross section of the first sacrificial layer 2 in the predetermined time.

On the other hand, in the first core material 3, corrosion is prevented and corrosion does not proceed within the corrosion protection range as described above, but corrosion progresses outside the corrosion protection range. In the first core material 3 which is an aluminum alloy, so-called “local corrosion” in which the film is locally destroyed due to the influence of the passivation film on the surface, which is a feature of the aluminum alloy, progresses. The appearance of this local corrosion can be grasped as a local corrosion mark by observing the surface.

[Product life of heat exchangers and outdoor units using aluminum material with zinc sacrificial layer as heat transfer tube]
Even in the aluminum material with a zinc sacrificial layer constituting the aluminum heat transfer tube of the outdoor heat exchanger 100, the place where the surface of the core material containing aluminum is outside the corrosion protection range is outside the corrosion protection range of the first core material 3 described above. Similar to the local corrosion that occurs, local corrosion occurs. When the passivation film is destroyed by the adhesion of a corrosion factor or the like and local corrosion occurs in the core material, the local corrosion proceeds arbitrarily inside the core material. In particular, since the passivation film is composed of aluminum oxide, the potential is higher than that of the core material containing aluminum. Therefore, the passivation film and the core material form a local battery, and corrosion on the core material side having a low potential is promoted. In addition, oxygen is present on the surface of the passivation film, and oxygen is deficient inside the core material. Therefore, a so-called oxygen concentration cell is formed between the passivation film and the inside of the core material, and corrosion on the core material side is also promoted. Therefore, in the aluminum heat transfer tube, when local corrosion occurs, the progress of the corrosion cannot be controlled, and the formation of through holes leads to refrigerant leakage, resulting in failure of the outdoor heat exchanger 100. Therefore, it is considered that setting the occurrence of local corrosion as the product life point is a safe design for ensuring the reliability of the outdoor heat exchanger 100 and the outdoor unit.

Therefore, in the corrosion resistance diagnostic component 1 according to the first embodiment, "the time when local corrosion occurs in the region within the corrosion protection range of the first sacrificial layer 2 with respect to the first core material 3" is set as the outdoor heat exchanger 100 and. This is the life point of the outdoor unit. Specifically, when the aluminum heat transfer tube of the outdoor heat exchanger 100 is a flat tube made of zinc-sprayed aluminum material, zinc is sprayed onto a pair of flat surfaces forming a part of the external shape. Therefore, in the flat tube of the zinc sprayed aluminum material, an exposed portion of the core material is formed on the side surface portion connecting the pair of flat surfaces from the beginning of production. That is, this side surface portion is the most disadvantageous portion in terms of corrosion resistance, and when the zinc sacrificial layer gradually disappears with aging, it is considered that local corrosion first appears in the exposed portion of the core material of the side surface portion. Therefore, the time point at which local corrosion appears on the side surface is defined as the life point of the outdoor heat exchanger 100.

[Achievement of product life due to decrease in corrosion protection range and detection by corrosion resistance diagnostic parts]
The outdoor heat exchanger 100 in which the aluminum material with a zinc sacrificial layer is applied to the heat transfer tube, and the outdoor unit having the outdoor heat exchanger 100, have increased the operating time after the installation of the air conditioner 200, in other words, the outdoor heat exchanger. With the passage of time after installing the 100 and the outdoor unit, product deterioration progresses with the progress of corrosion. Then, the outdoor heat exchanger 100 in which the aluminum material with the zinc sacrificial layer is applied to the heat transfer tube, and the outdoor unit having the outdoor heat exchanger 100 finally reach the product life. As the corrosion progresses in the aluminum material with the zinc sacrificial layer, the aluminum-zinc alloy disappears from the surface layer of the zinc sacrificial layer due to the corrosion, and the zinc concentration of the zinc sacrificial layer gradually decreases. Since the zinc sacrificial layer having a reduced zinc concentration has a high potential, the potential difference from the core material becomes small. That is, the movement of electrons between the anode and the cathode is attenuated, and the corrosion protection range of the zinc sacrificial layer in the core material is reduced.

When a predetermined period of time has passed since the outdoor heat exchanger 100 and the outdoor unit were installed and the zinc sacrificial layer disappears due to corrosion, the core material is exposed on the surface of the flat tube of the zinc sprayed aluminum material. Some are outside the anticorrosive range of the zinc sacrificial layer. Then, in the portion where the core material is exposed on the surface of the flat tube of the zinc sprayed aluminum material, local corrosion occurs in the region outside the corrosion protection range of the zinc sacrificial layer, and the life of the outdoor heat exchanger 100 and the outdoor unit is reached. It becomes. Therefore, the corrosion protection range of the zinc sacrificial layer in the flat tube of the initial zinc sprayed aluminum material manufactured is larger than the range in which the core material is exposed on the surface of the flat tube of the initial zinc sprayed aluminum material manufactured. It needs to be set so that it becomes.

FIG. 6 is a diagram showing a process of changing an exposed portion of the corrosion resistance diagnostic component according to the first embodiment of the present invention. FIG. 6 is a plan view of the corrosion resistance diagnostic component 1. Further, in FIG. 6, the concentration of zinc in the first sacrificial layer 2 which is the zinc sacrificial layer is shown by hatching, and the denser the hatching, the higher the zinc concentration. The black dots shown in FIG. 6 are local corrosion marks 5. Further, FIG. 6A shows the corrosion resistance diagnostic component 1 in a state before the operation of the outdoor unit having the outdoor heat exchanger 100 to which the corrosion resistance diagnostic component 1 is attached is started. In other words, FIG. 6A shows the corrosion resistance diagnostic component 1 in a state before the outdoor unit is installed. In other words, FIG. 6A shows the corrosion resistance diagnostic component 1 at the time of manufacture. FIG. 6B shows the corrosion resistance diagnostic component 1 after a lapse of a predetermined time from the installation of the outdoor unit. FIG. 6 (c) shows the corrosion resistance diagnostic component 1 after a lapse of a predetermined time from the state of FIG. 6 (b). FIG. 6D shows the corrosion resistance diagnostic component 1 after a lapse of a predetermined time from the state of FIG. 6C, and the corrosion resistance diagnostic component 1 indicates that the outdoor heat exchanger 100 and the outdoor unit have reached the end of their service life. It is a figure of the state shown.

As shown in FIG. 6, a first range 6a is arranged on the surface of the exposed portion 3a of the corrosion resistance diagnostic component 1 at a position adjacent to the first sacrificial layer 2 which is a zinc sacrificial layer. Specifically, the surface of the exposed portion 3a of the corrosion resistance diagnostic component 1 has a first range 6a within a specified distance L from the first sacrificial layer 2. Further, on the surface of the exposed portion 3a of the corrosion resistance diagnostic component 1, the second range 6b is arranged at a position opposite to the first sacrificial layer 2 with respect to the first range 6a. The specified distance L of the first range 6a is the position farthest from the zinc sacrificial layer in the range where the core material is exposed on the surface of the flat tube of the initial zinc sprayed aluminum material manufactured, and the zinc sacrificial layer. It is the same as the distance between. In other words, the specified distance L in the first range 6a is the position farthest from the zinc sacrificial layer within the range where the core material is exposed on the surface of the flat tube of the zinc sprayed aluminum material before the outdoor unit is installed. And the distance between the zinc sacrificial layer.

When the operation of the outdoor unit is started, in other words, when the operation of the air conditioner 200 is started, the local corrosion mark 5 appears in the second range 6b before the first range 6a. After that, a local corrosion mark 5 is generated in the first range 6a. Then, when the local corrosion mark 5 appears in the first range 6a, the outdoor heat exchanger 100 using the flat tube of the zinc sprayed aluminum material which is the material to be diagnosed is, in other words, the outdoor having the outdoor heat exchanger 100. Can be diagnosed as having a lifetime. In addition, the safety factor is estimated, and the specified distance L of the first range 6a is set from the zinc sacrificial layer within the range where the core material is exposed on the surface of the flat tube of the zinc sprayed aluminum material before the outdoor unit is installed. It may be longer than the distance between the farthest point and the zinc sacrificial layer.

Specifically, the corrosion resistance diagnostic component 1 shown in FIG. 6A is a state before the outdoor unit starts operation, and is locally located in both the first range 6a and the second range 6b of the exposed portion 3a. No corrosion marks 5 have appeared. When the outdoor unit is installed and the operation is started, the corrosion of the first sacrificial layer 2 which is the zinc sacrificial layer progresses. Then, the anticorrosion range of the first sacrificial layer 2 gradually decreases. Therefore, when the operation of the outdoor unit is started and a predetermined time elapses, as shown in FIG. 6B, the surface of the exposed portion 3a of the corrosion resistance diagnostic component 1 is outside the corrosion protection range of the first sacrificial layer 2. Local corrosion marks 5 appear in the second range 6b. Further, when a further time elapses from the state of FIG. 6B and the corrosion of the first sacrificial layer 2 further progresses, as shown in FIG. 6C, the surface of the exposed portion 3a of the corrosion resistance diagnostic component 1 is the first. Local corrosion marks 5 increase in the second range 6b, and local corrosion marks 5 appear at positions closer to the first range 6a than in FIG. 6 (b).

When more time has passed from the state of FIG. 6 (c) and the corrosion of the first sacrificial layer 2 further progresses, as shown in FIG. 6 (d), the surface of the exposed portion 3a of the corrosion resistance diagnostic component 1 is exposed to the third. Local corrosion marks 5 appear not only in the 2nd range 6b but also in the 1st range 6a. It is considered that this is because even in the flat tube of the zinc sprayed aluminum material of the outdoor heat exchanger 100, which is the material to be diagnosed, local corrosion appeared at the portion where the core material was exposed on the surface. After that, it is considered that the local corrosion rapidly progresses to the inside of the core material, and a through hole is formed in the flat tube of the zinc sprayed aluminum material. As described above, the method of detecting the appearance of the local corrosion mark 5 in the first range 6a is to use the outdoor heat exchanger 100 and the outdoor heat exchanger 100 in which a flat tube made of zinc sprayed aluminum, which is a diagnostic material, is used. This is a method for diagnosing the life of an outdoor unit.

It should be noted that this life diagnosis method can be performed by a person or by the above-mentioned corrosion resistance diagnostic device 300. A detailed example of this life diagnosis method will be described later in the fifth embodiment.

[Diagnosis of product remaining life using corrosion resistance diagnostic parts]
As the corrosion of the first sacrificial layer 2 which is the zinc sacrificial layer progresses, the corrosion protection range of the first sacrificial layer 2 with respect to the first core material 3 decreases. Along with this, local corrosion that has occurred outside the first range 6a of the exposed portion 3a also occurs within the first range 6a with the passage of time. As described above, when the corrosion resistance diagnostic component 1 is in such a state, it is determined that the outdoor heat exchanger 100 and the outdoor unit have reached the end of their service life. That is, the state in which local corrosion occurs in the first range 6a of the exposed portion 3a of the corrosion resistance diagnostic component 1 is the reaching point of the product life. By utilizing the corrosion progress process of the corrosion resistance diagnostic component 1, it is possible to diagnose the remaining life of the outdoor heat exchanger 100 and the outdoor unit. Specifically, by grasping the correlation between the appearance of the local corrosion mark 5 in the exposed portion 3a of the corrosion resistance diagnostic component 1 up to the reaching point of the product life and the progress of corrosion of the first sacrificial layer 2. By observing the corrosion resistance diagnostic component 1, it is possible to diagnose the remaining life of the outdoor heat exchanger 100 and the outdoor unit. Hereinafter, the diagnosis of the remaining life of the outdoor heat exchanger 100 and the outdoor unit using the corrosion resistance diagnostic component 1 will be described.

Of the progress process of corrosion of the corrosion resistance diagnostic component 1, the progress process of the first core material 3 is described in [Achievement of product life due to decrease in corrosion protection range and detection by corrosion resistance diagnostic component], as described in [Detection by corrosion resistance diagnostic component]. The surface of the exposed portion 3a of 3 may be observed. The entire surface of the first sacrificial layer 2 is corroded in the depth direction, but corrosion products may remain on the surface or fall off, making it difficult to measure the corrosion depth of the first sacrificial layer 2. There are many. Therefore, in the first embodiment, the corrosion depth of the first sacrificial layer 2 is measured as follows.

FIG. 7 is a vertical cross-sectional view of the corrosion resistance diagnostic component according to the first embodiment, showing a state in which the first sacrificial layer of the corrosion resistance diagnostic component is totally corroded. In addition, FIG. 7 also shows the shape of the corrosion resistance diagnostic component 1 in the state before the entire surface corrosion occurs in the first sacrificial layer 2 by the alternate long and short dash line.

When measuring the corrosion depth of the first sacrificial layer 2, the surface of the exposed portion 3a is used as a reference for height. In other words, the height of the surface of the exposed portion 3a is set to 0. When the height standard is defined in this way, the height from the surface of the exposed portion 3a to the surface of the first sacrificial layer 2 is d1 at the initial stage of production. This d1 is the cutting depth when the exposed portion 3a is formed when the corrosion resistance diagnostic component 1 is manufactured as described above.

Further, when measuring the corrosion depth of the first sacrificial layer 2, the reference point 7a and the reference line 7 are defined as shown in FIG. The reference point 7a is defined on the surface of the exposed portion 3a. That is, the height from the surface of the exposed portion 3a to the reference point 7a is 0. The reference point 7a is defined at a position within the corrosion protection range of the first sacrificial layer 2 until the end point of the product life so that the corrosion resistance diagnostic component 1 does not corrode until the end point of the product life. Therefore, it is preferable to set the reference point 7a at a position as close as possible to the boundary 2a between the first sacrificial layer 2 and the exposed portion 3a. By defining the reference point 7a at such a position, the height of the reference point 7a does not change until the corrosion resistance diagnostic component 1 reaches the end point of the product life, and the corrosion depth of the first sacrificial layer 2 is reduced. It can be measured accurately. The reference line 7 is a virtual straight line extending parallel to the surface of the initial first sacrificial layer 2 manufactured from the reference point 7a. That is, the height from the surface of the exposed portion 3a to the reference line 7 is also 0, which is the same as the reference point 7a.

The corroded portion 8 shown in FIG. 7 is a first sacrificial layer 2 portion that has disappeared due to corrosion over time. Further, the remaining portion 9 shown in FIG. 7 is the first sacrificial layer 2 portion remaining at that time. In the vertical cross section at an arbitrary distance L1 from the boundary 2a, the height from the reference line 7 to the surface of the remaining portion 9 is d2. Therefore, the height d of the corroded portion 8 in the cross section, in other words, the corrosion depth d of the first sacrificial layer 2 in the cross section is given by the following equation (5).
d = d1-d2 ... (5)
Therefore, by changing the distance L1 from the boundary 2a and measuring the corrosion depth d of the first sacrificial layer 2 at each position by the equation (5), the first sacrificial layer 2 at the time of measurement The corrosion depth can be grasped.

FIG. 8 is a diagram showing a process of changing the surface of the first sacrificial layer of the corrosion resistance diagnostic component according to the first embodiment of the present invention. The horizontal axis of FIG. 8 indicates the distance L1 from the boundary 2a. The vertical axis of FIG. 8 shows the corrosion depth d of the first sacrificial layer 2. Further, the line (a) shown in FIG. 8 shows the measurement result of the corrosion depth d of the first sacrificial layer 2 of the corrosion resistance diagnostic component 1 in the state of FIG. 6 (a). The line (b) shown in FIG. 8 shows the measurement result of the corrosion depth d of the first sacrificial layer 2 of the corrosion resistance diagnostic component 1 in the state of FIG. 6 (b). The line (c) shown in FIG. 8 shows the measurement result of the corrosion depth d of the first sacrificial layer 2 of the corrosion resistance diagnostic component 1 in the state of FIG. 6 (c). The line (d) shown in FIG. 8 shows the measurement result of the corrosion depth d of the first sacrificial layer 2 of the corrosion resistance diagnostic component 1 in the state of FIG. 6 (d).

As shown by the line (a) in FIG. 8, in the state before the outdoor heat exchanger 100 starts operation, the first sacrificial layer 2 of the corrosion resistance diagnostic component 1 is not corroded. When the outdoor unit is installed and the operation is started, as shown by the line (b) in FIG. 8, the corrosion of the first sacrificial layer 2 which is the zinc sacrificial layer progresses. Then, the anticorrosion range of the first sacrificial layer 2 gradually decreases. Therefore, as shown in FIG. 6B, local corrosion marks 5 appear on the surface of the exposed portion 3a of the corrosion resistance diagnostic component 1 in the second range 6b outside the corrosion protection range of the first sacrificial layer 2. .. Further, when a further time elapses from the state of FIG. 6 (b), as shown by the line (c) of FIG. 8, the corrosion of the first sacrificial layer 2 which is the zinc sacrificial layer progresses, and the corrosion depth d becomes deeper. Become. Then, as compared with the state of FIG. 6B, the anticorrosion range of the first sacrificial layer 2 is further reduced. Therefore, as shown in FIG. 6 (c), local corrosion marks 5 are increased in the second range 6b on the surface of the exposed portion 3a of the corrosion resistance diagnostic component 1, and the first range 6a is larger than that in FIG. 6 (b). Local corrosion marks 5 also appear at close positions.

When more time has passed from the state of FIG. 6 (c), as shown by the line (d) of FIG. 8, the corrosion of the first sacrificial layer 2 which is the zinc sacrificial layer further progresses, and the corrosion depth d becomes deeper. Become. Then, as compared with the state of FIG. 6C, the anticorrosion range of the first sacrificial layer 2 is further reduced. Therefore, as shown in FIG. 6D, local corrosion marks 5 appear not only in the second range 6b but also in the first range 6a on the surface of the exposed portion 3a of the corrosion resistance diagnostic component 1.

As described above, there is a correlation between the appearance of the local corrosion marks 5 in the exposed portion 3a over time and the corrosion depth d of the first sacrificial layer 2. Therefore, data such as a table showing the relationship between the appearance of the local corrosion marks 5 on the exposed portion 3a and the corrosion depth d of the first sacrificial layer 2 may be created. The appearance of the local corrosion marks 5 is, for example, the number of the local corrosion marks 5, the distance between the local corrosion marks 5 and the first sacrificial layer 2, and the like. By creating such data, the parameters indicating the corrosion state of the surface of the exposed portion 3a of the corrosion resistance diagnostic component 1 stored in the storage unit 314 of the corrosion resistance diagnostic device 300, and the corrosion depth of the first sacrificial layer 2 Can be associated.

Then, by creating such data, the corrosion depth d of the first sacrificial layer 2 can be diagnosed by comparing the appearance condition of the local corrosion mark 5 in the exposed portion 3a with the data, and the outdoor heat can be diagnosed. The remaining life of the exchanger 100 and the outdoor unit can be diagnosed. In other words, the remaining life of the outdoor heat exchanger 100 and the outdoor unit can be diagnosed by the local corrosion marks 5 appearing in the second range 6b of the exposed portion 3a. Further, by creating data showing the relationship between the passage of time and the corrosion depth d of the first sacrificial layer 2, the corrosion depth d of the first sacrificial layer 2 is measured, and the measured first sacrificial layer 2 is measured. By comparing the corrosion depth d of the above with the data, the remaining life of the outdoor heat exchanger 100 and the outdoor unit can be diagnosed.

For example, in the corrosion resistance diagnostic component 1 in a state where local corrosion does not occur in the first range 6a of the exposed portion 3a, the corrosion depth d of the first sacrificial layer 2 is observed. It is assumed that the corrosion depth d at this time is in the state shown by the line c1 in FIG. In this case, based on the above data, the time until the corrosion depth d shown by the line c1 becomes the state of the line (d) of FIG. 8 can be predicted. That is, the remaining life of the outdoor heat exchanger 100 and the outdoor unit can be diagnosed. Therefore, by measuring the corrosion resistance diagnostic component 1 as many times as possible between the state shown in FIG. 6A and the state shown in FIG. 6D, the remaining life of the outdoor heat exchanger 100 and the outdoor unit can be determined. Data for more accurate diagnosis can be created.

Here, in order to create data showing the relationship between the appearance of the local corrosion mark 5 in the exposed portion 3a and the corrosion depth d of the first sacrificial layer 2, the distance of the exposed portion 3a from the first sacrificial layer 2 is created. It is preferable to make the length as long as possible. The distance of the exposed portion 3a from the first sacrificial layer 2 is the distance in the side-by-side direction of the first sacrificial layer 2 and the exposed portion 3a in the exposed portion 3a. For example, in FIG. 6, the distance in the lateral direction of the exposed portion 3a. is there. This is because when the distance of the exposed portion 3a from the first sacrificial layer 2 is short, the zinc sacrificial layer is within the range where the core material is exposed on the surface of the flat tube of the zinc sprayed aluminum material before the outdoor unit is installed. This is because the distance of the exposed portion 3a from the first sacrificial layer 2 may be shorter than the distance between the portion farthest from the zinc sacrificial layer and the zinc sacrificial layer. In such a case, when the local corrosion mark 5 appears on the exposed portion 3a, the life of the outdoor heat exchanger 100 and the outdoor unit has already expired. Therefore, it is not possible to grasp the appearance of the local corrosion marks 5 in the exposed portion 3a until the outdoor heat exchanger 100 and the outdoor unit reach the end of their life. Therefore, in order to create data showing the relationship between the appearance of the local corrosion marks 5 in the exposed portion 3a and the corrosion depth d of the first sacrificial layer 2, the distance of the exposed portion 3a from the first sacrificial layer 2 is created. Is more than the distance between the zinc sacrificial layer and the farthest part from the zinc sacrificial layer within the range where the core material is exposed on the surface of the zinc sprayed aluminum flat tube before the outdoor unit is installed. , Needs to be long.

The method of diagnosing the remaining life of the outdoor heat exchanger 100 and the outdoor unit can be performed by a person or by the corrosion resistance diagnostic device 300 described above. A detailed example of this method of diagnosing the remaining life will be described later in the fifth embodiment.

[Example of product life evaluation using corrosion resistance diagnostic parts]
The corrosion resistance diagnostic component 1 according to the first embodiment was mounted on the outdoor unit, and the performance of the corrosion resistance diagnostic component 1 was verified. As described above, the material to be diagnosed according to the first embodiment is a flat tube of zinc sprayed aluminum material used as a heat transfer tube of the outdoor heat exchanger 100. In this embodiment, the corrosion resistance diagnostic component 1 was formed of the same member as the flat tube of the zinc sprayed aluminum material used as the heat transfer tube of the outdoor heat exchanger 100. Hereinafter, a method for manufacturing the corrosion resistance diagnostic component 1 will be specifically described.

FIG. 9 is a flowchart showing a manufacturing process of the corrosion resistance diagnostic component according to the first embodiment of the present invention. Further, FIG. 10 is a diagram showing a step of forming an exposed portion of the corrosion resistance diagnostic component according to the first embodiment of the present invention. Note that FIG. 10 is a view of the material 500 for the corrosion resistance diagnostic component, which is the corrosion resistance diagnostic component 1, observed from the direction of the arrow Z shown in FIG. 4, and is a diagram showing an end face of the material 500 for the corrosion resistance diagnostic component.

When manufacturing the corrosion resistance diagnostic component 1, first, in step S10, which is a preparation step, the material 500 for the corrosion resistance diagnostic component to be the corrosion resistance diagnostic component 1 is prepared. That is, the material 500 for the corrosion resistance diagnostic component in which the first sacrificial layer 2 is formed on the surface of the first core material 3 is prepared. In the first embodiment, the same member as the flat tube of the zinc sprayed aluminum material used as the heat transfer tube of the outdoor heat exchanger 100 is cut to a length of 50 mm to obtain the corrosion resistance diagnostic component material 500. The length of 50 mm is the length in the direction orthogonal to the paper surface in FIG. That is, the core material of the flat tube of the zinc sprayed aluminum material becomes the first core material 3 of the corrosion resistance diagnostic component 1 formed from the material 500 for the corrosion resistance diagnostic component. Further, the zinc sacrificial layer of the flat tube of the sprayed aluminum material becomes the first sacrificial layer 2 of the corrosion resistance diagnostic component 1 formed from the material 500 for the corrosion resistance diagnostic component. As shown in FIG. 10A, the material 500 for the corrosion resistance diagnostic component has a plate shape, a width of 10 mm, a thickness of 4 mm, a wall thickness of 500 μm, and a thickness of the first sacrificial layer 2 of 50 μm. ing. Further, in the material 500 for the corrosion resistance diagnostic component, the zinc concentration of the surface portion of the first sacrificial layer 2 is 10 wt%.

The zinc sprayed aluminum flat tube used as the heat transfer tube of the outdoor heat exchanger 100 may be purchased or manufactured by itself. In the case of self-manufacturing, step S10, which is a preparatory step, includes steps S11 and S12. Step S11 is a core material preparation step for preparing the first core material 3. In other words, step S11 is a step of preparing the same core material as the flat tube of the zinc sprayed aluminum material used as the heat transfer tube of the outdoor heat exchanger 100. Step S12 is a sacrificial layer forming step of forming the first sacrificial layer 2 on the surface of the first core material 3. In other words, in step S12, zinc spraying used as the heat transfer tube of the outdoor heat exchanger 100 is performed on the surface of the same core material as the flat tube of the zinc sprayed aluminum material used as the heat transfer tube of the outdoor heat exchanger 100. This is a process of forming the same zinc sacrificial layer as the zinc sacrificial layer of the aluminum material. This makes it possible to manufacture a flat tube made of zinc sprayed aluminum, which is used as a heat transfer tube for the outdoor heat exchanger 100.

When manufacturing the corrosion resistance diagnostic component 1, after step S10, which is a preparatory step, step S20, which is a forming step of forming the exposed portion 3a, is performed. In step S20, the surface of the first sacrificial layer 2 is removed from the boundary between the first sacrificial layer 2 and the first core material 3 to the inside of the first core material 3, and the position is adjacent to the first sacrificial layer 2. The exposed portion 3a is formed. In the first embodiment, the exposed portion 3a is formed by removing a part of the plate-shaped material 500 for the corrosion resistance diagnostic component by cutting. In this case, step S20, which is a forming step for forming the exposed portion 3a, includes steps S21 and S22.

As shown in FIG. 10B, step S21 is a first cutting step of cutting a flat surface portion of the corrosion resistance diagnostic component material 500 and exposing the first core material 3 on the flat surface portion. In the first embodiment, the range from the end surface of the material 500 for the corrosion resistance diagnostic component to 25 mm in the depth direction of the paper surface in FIG. 10 is cut by 120 μm from the surface of the first sacrificial layer 2 in the direction of the first core material 3 to expose the exposed portion. Form 3a. This cutting process is performed by, for example, milling. As described above, the thickness of the first sacrificial layer 2 is 50 μm. Therefore, the flat portion of the exposed portion 3a was formed by cutting the flat portion of the material 500 for the corrosion resistance diagnostic component by cutting 120 μm from the surface of the first sacrificial layer 2 in the direction of the first core material 3. In the range, zinc can be completely removed.

As described above, in the case of a flat tube made of zinc sprayed aluminum material, zinc is sprayed onto a pair of flat surfaces forming a part of the outer shape. Zinc sprayed on the flat surface also diffuses to a part of the side surface during the heat treatment. Therefore, as shown in FIG. 10B, after the flat surface portion of the material 500 for the corrosion resistance diagnostic component is cut, there is a zinc residual region 10 in which zinc remains in a part of the side surface portion. .. Therefore, as shown in FIG. 10C, the zinc residual region 10 is removed in step S22, which is the second cutting step. Specifically, in step S22, which is the second cutting step, both side surface portions of the corrosion resistance diagnostic component material 500 are cut so as to be continuous with the exposed portion of the first core material 3 in the flat surface portion, and the both side surface portions are cut. The first core material 3 is exposed. As a result, zinc can be completely removed from the surface of the exposed portion 3a, and the corrosion resistance diagnostic component 1 is completed.

In the corrosion resistance diagnostic component 1 manufactured in this way, the first range 6a was determined as follows. In other words, the defined distance L from the first sacrificial layer 2 in the exposed portion 3a of the corrosion resistance diagnostic component 1 shown in FIG. 6 was determined as follows. As described above, in the case of a flat tube made of zinc sprayed aluminum material, zinc is sprayed onto a pair of flat surfaces forming a part of the outer shape. Therefore, in the flat tube of the initial zinc sprayed aluminum material manufactured, there is a possibility that the core material is exposed over the entire surface of the side surface portion.

Here, as described above, the flat tube of the zinc sprayed aluminum material used as the heat transfer tube of the outdoor heat exchanger 100 has a thickness of 4 mm. In other words, in the flat tube made of zinc sprayed aluminum used as the heat transfer tube of the outdoor heat exchanger 100, the distance between the surfaces of the pair of flat surfaces is 4 mm. Further, as can be seen from FIG. 10, the flat tube of the zinc sprayed aluminum material used as the heat transfer tube of the outdoor heat exchanger 100 has an arcuate cross-sectional shape of the side surface portion connecting the pair of flat surfaces. .. Therefore, the cross-sectional shape of the side surface of the flat tube of the zinc sprayed aluminum material used as the heat transfer tube of the outdoor heat exchanger 100 is an arc shape having a radius of 2 mm. The arc length of this side surface portion is 6.28 mm.

Further, in the side portion where the core material is exposed on the surface, local corrosion is suppressed while it exists within the corrosion protection range of the zinc sacrificial layer formed on the flat surface portion. Therefore, since the central position of the side surface portion in the cross-sectional shape is the position farthest from both the flat surface portions on the side surface portion, the corrosion protection range is reached earliest and local corrosion occurs. That is, local corrosion occurs earliest at a position where the distance on the surface from the flat surface portion is 3.14 mm on the side surface portion. Therefore, in the first embodiment, the defined distance L from the first sacrificial layer 2 in the exposed portion 3a of the corrosion resistance diagnostic component 1 shown in FIG. 6 is set to 3.14 mm.

The corrosion resistance diagnostic component 1 configured in this way is different from the conventional component that diagnoses the product life of the heat exchanger using the aluminum heat transfer tube, and zinc is completely removed from the exposed portion 3a. Therefore, in the corrosion resistance diagnostic component 1 according to the first embodiment, the corrosion status of the material to be diagnosed can be diagnosed more accurately than before based on the corrosion status of the surface of the exposed portion 3a. Therefore, by using the corrosion resistance diagnostic component 1 according to the first embodiment, the life and the remaining life of the outdoor heat exchanger 100 and the outdoor unit having the outdoor heat exchanger 100 can be accurately diagnosed. Further, the conventional parts for diagnosing the product life of the heat exchanger using the aluminum heat transfer tube have been manufactured with a member different from the material to be diagnosed. For this reason, in order to accurately diagnose the corrosion state of the material to be diagnosed, the conventional parts require a complicated design, and the manufacturing cost has increased. On the other hand, the corrosion resistance diagnostic component 1 according to the first embodiment is made of the same member as the flat tube of the zinc sprayed aluminum material used as the heat transfer tube of the outdoor heat exchanger 100 which is the material to be diagnosed. It is possible to more accurately diagnose the life of the outdoor heat exchanger 100 and the outdoor unit having the outdoor heat exchanger 100 while suppressing the manufacturing cost.

FIG. 11 is a flowchart showing a composite cycle test performed in the first embodiment of the present invention.
The corrosion resistance diagnostic component 1 manufactured as described above was provided in the outdoor unit of the air conditioner 200 together with the outdoor heat exchanger 100, and the combined cycle test shown in FIG. 11 was carried out as an accelerated test for reproducing the corrosion morphology in the salt-damaged area. ..

First, in step S31, salt water was sprayed. Specifically, the installation environment of the outdoor unit was an environment with a temperature of 35 ° C. and a relative humidity of 100%. Then, in this state, the outdoor unit was operated for 2 hours while spraying an aqueous solution having a salt concentration of 5% by weight on the outdoor unit. In step S32 after step S31, a drying process was performed. Specifically, the installation environment of the outdoor unit was set to an environment having a temperature of 60 ° C. and a relative humidity of 30%. Then, in this state, the outdoor unit was operated for 4 hours. In step S33 after step S32, a wet treatment was performed. Specifically, the installation environment of the outdoor unit was set to an environment having a temperature of 50 ° C. and a relative humidity of 95%. Then, in this state, the outdoor unit was operated for 2 hours.

In step S34 after step S33, it is determined whether or not the operating time of the outdoor unit has reached the specified time. If the operating time of the outdoor unit has not reached the specified time, the process returns to step S31. On the other hand, when the operating time of the outdoor unit has reached the specified time, the combined cycle test is terminated. That is, in the combined cycle test performed in the first embodiment, the processes of steps S31 to S33 are repeated until the operating time of the outdoor unit reaches the specified time. In the first embodiment, the specified time is set to 2000 hours.

While performing the above-mentioned composite cycle test, the corrosion state of the corrosion resistance diagnostic component 1 was periodically observed. In the first embodiment, the corrosion state of the corrosion resistance diagnostic component 1 was observed every 250 hours. Further, the periodic observation of the corrosion state of the corrosion resistance diagnostic component 1 was repeated until the local corrosion mark 5 was generated in the first range 6a of the exposed portion 3a of the corrosion resistance diagnostic component 1.

As a result of observing the corrosion state of the corrosion resistance diagnostic component 1 with the elapsed operation time, 250 hours after the start of operation of the outdoor unit, a local corrosion mark 5 appears in the second range 6b of the exposed portion 3a of the corrosion resistance diagnostic component 1. I confirmed how it was appearing. Further, in the corrosion resistance diagnostic component 1, the corrosion depth of the first sacrificial layer 2 which is the zinc sacrificial layer was measured. As a result of observing the corrosion resistance diagnostic component 1 even after 500 hours, 750 hours, 1000 hours, and 1250 hours have passed since the start of operation of the outdoor unit, a local corrosion mark 5 was found in the second range 6b of the exposed portion 3a. I confirmed how it was occurring. Further, it was confirmed that as the operation time increased, the appearance range of the local corrosion marks 5 expanded toward the first range 6a of the exposed portion 3a in the second range 6b of the exposed portion 3a. In addition, it was confirmed that the corrosion of the first sacrificial layer 2 progressed in the depth direction as the operating time increased.

As a result of observing the corrosion resistance diagnostic component 1 1500 hours after the start of operation of the outdoor unit, it was confirmed that the local corrosion mark 5 appeared in the first range 6a of the exposed portion 3a. Further, when the first sacrificial layer 2 was observed in the corrosion resistance diagnostic component 1, it was confirmed that the first sacrificial layer 2 disappeared almost over the entire surface due to corrosion. Since the first sacrificial layer 2 disappeared and the anticorrosion function for the exposed portion 3a disappeared, it is considered that local corrosion progressed within the first range 6a of the exposed portion 3a. Similarly, as a result of observing the heat transfer tube of the outdoor heat exchanger 100 1500 hours after the start of operation of the outdoor unit, local corrosion appeared at a place where the core material was exposed on the surface, and the corrosion resistance diagnostic component 1 was covered. It was verified that the product life using the diagnostic material can be accurately diagnosed.

From the above, it is determined that 1500 hours from the start of operation of the outdoor unit is the life of the outdoor heat exchanger 100 and the outdoor unit in this combined cycle test. Then, for example, when it is known that this combined cycle test proceeds at a predetermined acceleration ratio with respect to the corrosion of the outdoor heat exchanger 100 and the outdoor unit in a certain environment, the outdoor heat exchange is performed based on the acceleration ratio. The life of the vessel 100 and the outdoor unit can be estimated. Further, based on the test results of this composite cycle test, data showing the relationship between the appearance of the local corrosion marks 5 in the exposed portion 3a and the corrosion depth d of the first sacrificial layer 2 is created in advance. , The remaining life of the outdoor heat exchanger 100 and the outdoor unit can be diagnosed based on the data.

Embodiment 2.
The member used for the corrosion resistance diagnostic component 1 is not limited to the member shown in the first embodiment. Further, the manufacturing method of the corrosion resistance diagnostic component 1 is not limited to the manufacturing method shown in the first embodiment. In the second embodiment, another example of a member that can be used for the corrosion resistance diagnostic component 1 will be introduced. Further, in the second embodiment, an example of another manufacturing method of the corrosion resistance diagnostic component 1 will be described. In the second embodiment, items not particularly described will be the same as those in the first embodiment, and the same functions and configurations as those in the first embodiment will be described using the same reference numerals.

The outdoor unit includes a refrigerant pipe through which the refrigerant flowing into the outdoor heat exchanger 100 or the refrigerant flowing out of the outdoor heat exchanger 100 flows. A part of this refrigerant pipe may be made of an aluminum material with a zinc sacrificial layer. For example, the refrigerant distributor may form a part of the refrigerant piping of the outdoor unit. The refrigerant distributor includes a main pipe and a plurality of branch pipes connected to the main pipe. Since the refrigerant distributor has a complicated shape, it is difficult to form a sacrificial layer by zinc spraying. Therefore, in the refrigerant distributor, a zinc-containing paint is applied to the surface of the core material containing aluminum, and a zinc sacrificial layer is formed on the surface of the core material.

Further, the heat transfer pipe is a part of the refrigerant pipe of the outdoor heat exchanger 100, and the outdoor heat exchanger 100 also includes a refrigerant pipe other than the heat transfer pipe, such as a refrigerant pipe connecting each heat transfer pipe. An aluminum material with a zinc sacrificial layer may be used for a refrigerant pipe other than such a heat transfer pipe. For the refrigerant piping other than the heat transfer tube, a circular tube having a simple shape may be used even when a flat tube made of zinc sprayed aluminum is used as the heat transfer tube in order to improve the performance of the outdoor heat exchanger 100. .. When the refrigerant pipe other than the heat transfer pipe is a circular pipe made of an aluminum material with a zinc sacrificial layer, a zinc-sprayed aluminum material can be used, or an aluminum clad material can be used.

It is also possible to manufacture the corrosion resistance diagnostic component 1 by using the same member as the refrigerant pipe of the outdoor unit made of the aluminum material with the zinc sacrificial layer. In this case, the refrigerant pipe of the outdoor unit made of the aluminum material with the zinc sacrificial layer is the material to be diagnosed. It is also possible to manufacture the corrosion resistance diagnostic component 1 by using the same member as the refrigerant pipe other than the heat transfer pipe of the outdoor heat exchanger 100 made of the aluminum material with the zinc sacrificial layer. In this case, the refrigerant pipe other than the heat transfer pipe of the outdoor heat exchanger 100 made of the aluminum material with the zinc sacrificial layer is the material to be diagnosed. In the second embodiment, a method of manufacturing the corrosion resistance diagnostic component 1 by the same member as the refrigerant pipe formed of the aluminum material with the zinc sacrificial layer will be described.

When the corrosion resistance diagnostic component 1 is manufactured using the same member as the flat tube of the aluminum material with the zinc sacrificial layer, since the zinc sacrificial layer is formed on the flat surface, the zinc sacrificial layer is removed by cutting and the exposed portion 3a. Can be formed. On the other hand, in the case where the corrosion resistance diagnostic component 1 is manufactured using the same member as the refrigerant pipe formed of the aluminum material with the zinc sacrificial layer described above in the second embodiment, it is difficult to remove the zinc sacrificial layer by cutting. There is. In this case, a method of removing the zinc sacrificial layer by chemical etching to form the exposed portion 3a is effective. In chemical etching, the chemical solution is brought into contact with the aluminum material, and the two react with each other to dissolve the aluminum material. If this chemical etching is applied to an aluminum material with a zinc sacrificial layer, the corrosion resistance diagnostic component 1 can be manufactured. That is, the core material can be exposed to the surface by bringing the chemical solution into contact with the surface of the same member as the refrigerant pipe made of the aluminum material with the zinc sacrificial layer. Then, zinc can be completely removed from the surface of the exposed core material, and the exposed portion 3a can be formed.

When the same member as the refrigerant pipe made of the aluminum material with the zinc sacrificial layer has a uniform shape such as a circular pipe, the member may be immersed in a chemical solution to expose the core material to the surface. On the other hand, when the same member as the refrigerant pipe made of the aluminum material with the zinc sacrificial layer has a complicated shape like a refrigerant distributor, the member is simply immersed in a chemical solution to expose the core material to the surface. Is difficult. In such a case, for example, the core material may be exposed to the surface by applying gauze or the like containing a chemical solution to the portion where the exposed portion 3a is to be formed and chemically etching the portion to which the gauze or the like is applied. For example, when the same member as the refrigerant pipe made of the aluminum material with the zinc sacrificial layer has a complicated shape, masking is applied to the part where the zinc sacrificial layer is to be left, and the chemical solution is brought into contact with the other parts. The core material may be exposed on the surface.

The chemical solution used for chemical etching may be any material that dissolves the aluminum material, and an acidic chemical solution having a pH of 5 or less or an alkaline chemical solution having a pH of 10 or more is preferable. The time required for the aluminum material with the zinc sacrificial layer to come into contact with the chemical solution to expose the core material may be appropriately determined depending on the chemical solution to be used and the aluminum material with the zinc sacrificial layer.

As described above, since the corrosion resistance diagnostic component 1 according to the second embodiment is also made of the same member as the material to be diagnosed, the life of the outdoor heat exchanger 100 and the outdoor unit is accurately diagnosed while suppressing the manufacturing cost. be able to.

In addition, even when the exposed portion 3a is formed by cutting or when the exposed portion 3a is formed by chemical etching, if the surface roughness of the exposed portion 3a is large, the local corrosion mark 5 can be detected. It can be difficult. Therefore, it is preferable that after the exposed portion 3a is formed by cutting or chemical etching, the exposed portion 3a is subjected to electrolytic polishing, chemical polishing, buffing or the like to reduce the surface roughness of the exposed portion 3a. As a result, the local corrosion mark 5 appearing on the exposed portion 3a can be accurately confirmed, and the diagnostic accuracy of the corrosion state of the product in which the material to be diagnosed is used can be improved.

Embodiment 3.
In the first embodiment, the corrosion depth of the first sacrificial layer 2 which is a zinc sacrificial layer was measured in the cross section, and the progress of corrosion of the first sacrificial layer 2 with the passage of time was grasped. However, the method for grasping the progress of corrosion of the first sacrificial layer 2 with the passage of time is not limited to this method. In the third embodiment, some other examples of grasping the progress of corrosion of the first sacrificial layer 2 with the passage of time will be introduced. In the third embodiment, items not particularly described are the same as those of the first embodiment or the second embodiment, and the same reference numerals are used for the same functions and configurations as those of the first embodiment or the second embodiment. Will be described.

[Understanding the progress of corrosion of the first sacrificial layer due to the amount of corrosion]
For example, it is possible to grasp the progress of corrosion of the first sacrificial layer 2 with the passage of time based on the amount of corrosion of the first sacrificial layer 2. In the following, two methods for grasping the progress of corrosion of the first sacrificial layer 2 over time based on the amount of corrosion of the first sacrificial layer 2 will be introduced.

The first method is a method of grasping the amount of corrosion of the first sacrificial layer 2 by measuring the area of the region where the first sacrificial layer 2 is corroded in a predetermined cross section of the first sacrificial layer 2. As for the corrosion of the first sacrificial layer 2, the entire surface corrosion progresses in the depth direction. Therefore, it is considered possible to convert the corrosion amount of the first sacrificial layer 2 as a whole by setting a predetermined cross section and measuring the corroded area of the first sacrificial layer 2 in this cross section. If the ratio of the corroded portion 8 and the remaining portion 9 is grasped by binarization or the like in the predetermined cross section, the corroded portion 8 of the entire first sacrificial layer 2 can be derived. Therefore, as a result, it is possible to grasp the progress of corrosion of the first sacrificial layer 2 with the passage of time.

Then, by creating data such as a table showing the relationship between the appearance of the local corrosion marks 5 in the exposed portion 3a and the corrosion area in the predetermined cross section of the first sacrificial layer 2, the storage unit 314 of the corrosion resistance diagnostic device 300 can be used. It is possible to associate the stored parameter indicating the corrosion state of the surface of the exposed portion 3a of the corrosion resistance diagnostic component 1 with the corrosion area in the predetermined cross section of the first sacrificial layer 2. Then, by creating such data, it is possible to diagnose the remaining life of the outdoor heat exchanger 100 and the outdoor unit by comparing the appearance condition of the local corrosion mark 5 in the exposed portion 3a with the data. it can. In other words, the remaining life of the outdoor heat exchanger 100 and the outdoor unit can be diagnosed by the local corrosion marks 5 appearing in the second range 6b of the exposed portion 3a.

Further, by creating data showing the relationship between the passage of time and the corrosion area in the predetermined cross section of the first sacrificial layer 2, the corrosion area in the predetermined cross section of the first sacrifice layer 2 is measured and the measured first sacrifice. By comparing the corroded area in the predetermined cross section of the layer 2 with the data, the remaining life of the outdoor heat exchanger 100 and the outdoor unit can be diagnosed.

The second method is a method of grasping the amount of corrosion of the first sacrificial layer 2 by measuring the weight of the corrosion resistance diagnostic component 1. The weight of the corrosion resistance diagnostic component 1 before the outdoor unit starts operation and the weight of the corrosion resistance diagnostic component 1 after the outdoor unit has been operated for a predetermined time are measured, and the weight change of the corrosion resistance diagnostic component 1 is used to determine the first sacrificial layer 2 Understand the amount of corrosion. The amount of corrosion of the first core material 3 is on the order of μm, which is smaller than the amount of corrosion of the first sacrificial layer 2. Therefore, the change in weight of the corrosion resistance diagnostic component 1 can be regarded as the amount of corrosion of the first sacrificial layer 2. Therefore, the amount of corrosion of the first sacrificial layer 2 can be grasped from the weight change of the corrosion resistance diagnostic component 1. Therefore, as a result, it is possible to grasp the progress of corrosion of the first sacrificial layer 2 with the passage of time.

When the first sacrificial layer 2 is corroded, corrosive organisms are deposited on the corrosion resistance diagnostic component 1. Therefore, when measuring the weight of the corrosion resistance diagnostic component 1, it is necessary to remove corrosive organisms. As the removing method, the "chemical corrosion product removing method" in the JISZ2371 standard or mechanical removal using a brush or the like is suitable. After the operation of the outdoor unit is started, corrosion products are removed from the corrosion resistance diagnostic component 1 by these methods, and the weight of the corrosion resistance diagnostic component is measured. Then, by comparing this weight with the weight of the corrosion resistance diagnostic component 1 before the outdoor unit starts operation, it is possible to grasp the progress of corrosion of the first sacrificial layer 2 with the passage of time.

Then, by creating data such as a table showing the relationship between the appearance of the local corrosion mark 5 in the exposed portion 3a and the weight change of the corrosion resistance diagnostic component 1, the data is stored in the storage unit 314 of the corrosion resistance diagnostic device 300. A parameter indicating a corrosion state on the surface of the exposed portion 3a of the corrosion resistance diagnostic component 1 can be associated with a weight change of the corrosion resistance diagnostic component 1. Then, by creating such data, it is possible to diagnose the remaining life of the outdoor heat exchanger 100 and the outdoor unit by comparing the appearance condition of the local corrosion mark 5 in the exposed portion 3a with the data. it can. In other words, the remaining life of the outdoor heat exchanger 100 and the outdoor unit can be diagnosed by the local corrosion marks 5 appearing in the second range 6b of the exposed portion 3a.

In addition, by creating data showing the relationship between the passage of time and the weight change of the corrosion resistance diagnostic component 1, the weight change of the corrosion resistance diagnostic component 1 is measured, and the measured weight change of the corrosion resistance diagnostic component 1 and the data The remaining life of the outdoor heat exchanger 100 and the outdoor unit can be diagnosed by comparing the above.

[Measurement of corrosion depth by depth of focus method]
In the first embodiment, the corrosion depth of the first sacrificial layer 2 which is the zinc sacrificial layer was measured in the cross section. The method for measuring the corrosion depth of the first sacrificial layer 2 is not limited to this method, and the corrosion depth of the first sacrificial layer 2 may be measured by, for example, the focal depth method. When measuring the corrosion depth of the first sacrificial layer 2 by the depth of focus method, first, as described above, corrosive organisms are removed from the corrosion resistance diagnostic component 1. Then, the corrosion depth of the first sacrificial layer 2 is measured by the depth of focus method for the corrosion resistance diagnostic component 1 from which the corrosion products have been removed. In this method, the corrosion depth at each position can be continuously measured from the boundary between the first sacrificial layer 2 and the exposed portion 3a, and the corrosion depth of the first sacrificial layer 2 can be easily measured. Therefore, it is a useful method as a method for measuring the corrosion depth of the first sacrificial layer 2.

Embodiment 4.
In the refrigerant piping of aluminum material with a zinc sacrificial layer provided in the outdoor unit, corrosion is more likely to proceed in the portion where the amount of flying salt, which is a corrosion factor of atmospheric corrosion, is large. Therefore, in order to make a reliable life diagnosis, in other words, in order to ensure that the product life can be diagnosed before a through hole is formed in the refrigerant pipe of the aluminum material with a zinc sacrificial layer, it is the most important. It is preferable to install the corrosion resistance diagnostic component 1 at a position where corrosion easily progresses. In the fourth embodiment, an example of a suitable installation position of the corrosion resistance diagnostic component 1 will be introduced. In the fourth embodiment, the items not specifically described are the same as those of the first to third embodiments, and the same functions and configurations as those of the first to third embodiments are the same. It will be described using the code of.

For example, when an aluminum material with a zinc sacrificial layer is used in at least a part of the refrigerant pipe of the outdoor heat exchanger 100, the refrigerant pipe of the aluminum material with a zinc sacrificial layer is the place where the flying salt is most likely to adhere. , Corrosion resistance diagnostic component 1 may be installed. For example, when the corrosion resistance diagnostic component 1 is formed of the zinc sprayed aluminum material used as the heat transfer tube of the outdoor heat exchanger 100, the corrosion resistance diagnostic component 1 may be installed at the following positions.

FIG. 12 is a side view showing a part of the core portion of the outdoor heat exchanger according to the fourth embodiment of the present invention.
The core portion 400 of the outdoor heat exchanger 100 according to the fourth embodiment includes a heat transfer tube 411. The heat transfer tube 411 is a flat tube made of zinc sprayed aluminum material. Further, in order to improve the amount of heat exchange between the refrigerant flowing in the heat transfer tube 411 and the outside air, a plurality of fins 412 made of a material containing aluminum, for example, are attached to the surface of a part of the heat transfer tube 411. ing. That is, the heat transfer tube 411 has a surface exposed portion 413 in which the fins 412 are not attached to the surface and a fin contact portion 414 whose surface is covered with the fins 412.

In the exposed surface portion 413, the surface of the heat transfer tube 411 is not covered with the fins 412. Therefore, the exposed surface portion 413 of the heat transfer tube 411 is more likely to have flying salt adhered to it than the fin contact portion 414. Therefore, the exposed surface portion 413 of the heat transfer tube 411 is more likely to corrode than the fin contact portion 414. Therefore, when the corrosion resistance diagnostic component 1 is formed of the zinc sprayed aluminum material used as the heat transfer tube of the outdoor heat exchanger 100, the corrosion resistance diagnostic component 1 may be attached to the exposed surface portion 413 of the heat transfer tube 411. As a result, it is possible to reliably diagnose that the outdoor heat exchanger 100 has reached the end of its life before the through hole is formed in the heat transfer tube 411, and the reliability of the product life diagnosis using the corrosion resistance diagnostic component 1 is improved.

Further, the installation position of the corrosion resistance diagnostic component 1 may be examined by paying attention to the wind flow in the outdoor unit during the operation of the outdoor unit. The part where the wind speed is highest in the outdoor unit when the outdoor unit is operating can be considered to be the part where the flying salt is most likely to adhere in the outdoor unit when the outdoor unit is operating. Therefore, by installing the corrosion resistance diagnostic component 1 in the part where the wind speed is highest in the outdoor unit during the operation of the outdoor unit, the corrosion resistance diagnostic component 1 is less corroded than the refrigerant piping of the aluminum material with the zinc sacrificial layer provided in the outdoor unit. Progress will be faster. Therefore, even if the corrosion resistance diagnostic component 1 is installed at such a position, it is possible to reliably diagnose that the outdoor unit has reached the end of its life before the through hole is formed in the refrigerant pipe of the aluminum material with the zinc sacrificial layer. The reliability of product life diagnosis using the corrosion resistance diagnostic component 1 is improved.

Embodiment 5.
As described above, the life and remaining life of the outdoor heat exchanger 100 and the outdoor unit can be diagnosed by a person or by the corrosion resistance diagnostic device 300. In the fifth embodiment, an example of diagnosing the life and remaining life of the outdoor heat exchanger 100 and the outdoor unit performed by a person, and diagnosing the life and remaining life of the outdoor heat exchanger 100 and the outdoor unit performed by the corrosion resistance diagnostic device 300. Here is an example. In the fifth embodiment, the items not particularly described are the same as those of the first to fourth embodiments, and the same functions and configurations as those of the first to fourth embodiments are the same. It will be described using the code of.

When a person diagnoses the life of the outdoor heat exchanger 100 and the outdoor unit, a person such as a maintenance maker confirms the local corrosion mark 5 appearing on the exposed portion of the corrosion resistance diagnostic component 1. The local corrosion mark 5 appearing on the exposed portion 3a of the corrosion resistance diagnostic component 1 is visually confirmed, for example. When visually confirming the local corrosion mark 5 appearing on the exposed portion 3a, for example, a person temporarily removes the corrosion resistance diagnostic component 1 and confirms the local corrosion mark 5 appearing on the exposed portion 3a of the corrosion resistance diagnostic component 1. Further, for example, when the corrosion resistance diagnostic component 1 is installed at a position where the local corrosion mark 5 appearing on the exposed portion 3a can be directly visually observed, a person does not remove the corrosion resistance diagnostic component 1 and the local corrosion appearing on the exposed portion 3a. Trace 5 may be confirmed. Further, for example, by installing a mirror or the like, a person can confirm the local corrosion mark 5 appearing on the exposed portion 3a without removing the corrosion resistance diagnostic component 1. Further, for example, when the corrosion resistance diagnostic device 300 provided with at least the photographing unit 312 and the detecting unit 313 is provided, a person can also visually check the image data of the detecting unit 313 to see the local corrosion marks appearing on the exposed unit 3a. 5 can be confirmed. Then, when a person confirms the local corrosion mark 5 in the first range 6a of the exposed portion 3a, he / she diagnoses that the outdoor heat exchanger 100 and the outdoor unit have reached the end of their service life.

When it is diagnosed that the outdoor heat exchanger 100 and the outdoor unit have reached the end of their service life, maintenance of the outdoor unit may be performed. Maintenance of the outdoor unit includes replacement of the refrigerant pipe of the aluminum material with the zinc sacrificial layer, repair of a locally corroded portion generated in the refrigerant pipe of the aluminum material with the zinc sacrificial layer, replacement of the outdoor heat exchanger 100, and the like.

When a person diagnoses the remaining life of the outdoor heat exchanger 100 and the outdoor unit, the corrosion resistance diagnostic component 1 is once brought back to an environment where the progress of corrosion of the first sacrificial layer 2 can be measured. Then, for example, when data showing the relationship between the passage of time and the corrosion depth d of the first sacrificial layer 2 is created, a person measures the corrosion depth d of the first sacrificial layer 2. Then, the remaining life of the outdoor heat exchanger 100 and the outdoor unit is diagnosed by comparing the measured corrosion depth d of the first sacrificial layer 2 with the data. Further, for example, when data showing the relationship between the passage of time and the corroded area in the predetermined cross section of the first sacrificial layer 2 is created, a person measures the corroded area in the predetermined cross section of the first sacrificial layer 2. Then, the remaining life of the outdoor heat exchanger 100 and the outdoor unit is diagnosed by comparing the measured corroded area in the predetermined cross section of the first sacrificial layer 2 with the data. Further, for example, when data showing the relationship between the passage of time and the weight change of the corrosion resistance diagnostic component 1 is created, a person measures the weight change of the corrosion resistance diagnostic component 1. Then, the remaining life of the outdoor heat exchanger 100 and the outdoor unit is diagnosed by comparing the measured weight change of the corrosion resistance diagnostic component 1 with the data.

A case where the corrosion resistance diagnostic device 300 diagnoses the life of the outdoor heat exchanger 100 and the outdoor unit will be described. The local corrosion marks 5 appearing on the exposed portion 3a of the corrosion resistance diagnostic component 1 are different in color and shape from the first core material 3. Therefore, the detection unit 313 converts the image data of the exposed portion 3a photographed by the photographing unit 312 into image data composed of at least one of the color and the shape, and locally corrodes the exposed portion 3a. The trace 5 is used as discriminable data.

The image data generated by the detection unit 313 is sent to the storage unit 314 and the comparison unit 315 at predetermined time intervals, for example. Each time the image data is sent from the detection unit 313, the comparison unit 315 compares the image data with the image data stored in the storage unit 314. Then, when the comparison unit 315 confirms that the local corrosion mark 5 appears in the first range 6a of the exposed portion 3a, it diagnoses that the outdoor heat exchanger 100 and the outdoor unit have reached the end of their service life. In addition, the notification unit 316 notifies that the outdoor heat exchanger 100 and the outdoor unit have reached the end of their service life.

When the corrosion resistance diagnostic device 300 diagnoses the remaining life of the outdoor heat exchanger 100 and the outdoor unit, data for guiding the remaining life of the outdoor heat exchanger 100 and the outdoor unit is stored in advance in the storage unit 314. The data that leads to the remaining life of the outdoor heat exchanger 100 and the outdoor unit is, for example, data showing the relationship between the appearance of the local corrosion marks 5 in the exposed portion 3a and the corrosion depth d of the first sacrificial layer 2. The data showing the relationship between the appearance of the local corrosion mark 5 in the exposed portion 3a described above and the corrosion area in the predetermined cross section of the first sacrificial layer 2, or the appearance condition of the local corrosion mark 5 in the exposed portion 3a described above. This is data showing the relationship between the corrosion resistance and the weight change of the corrosion resistance diagnostic component 1. Further, for example, data showing the relationship between the appearance of the local corrosion mark 5 in the exposed portion 3a and the remaining life of the outdoor heat exchanger 100 and the outdoor unit can be used as data for deriving the remaining life of the outdoor heat exchanger 100 and the outdoor unit. It may be stored in the storage unit 314.

When the image data is sent from the detection unit 313, the comparison unit 315 shows the appearance of the local corrosion mark 5 in the exposed unit 3a in the data, and the outdoor heat exchanger 100 and the outdoor heat exchanger 100 stored in the storage unit 314. The remaining life of the outdoor heat exchanger 100 and the outdoor unit is diagnosed by comparing with the data that derives the remaining life of the machine. In addition, the notification unit 316 notifies the remaining life of the outdoor heat exchanger 100 and the outdoor unit.

In this way, by using the corrosion resistance diagnostic device 300, it is possible to diagnose the remaining life of the outdoor heat exchanger 100 and the outdoor unit without performing human work and judgment.

Embodiment 6.
Using the corrosion resistance diagnostic component 1, grasp the presence or absence of corrosive substances in the atmosphere in the installation environment of the outdoor unit, and the degree of influence of the corrosive substances in the air on the members including aluminum provided in the outdoor unit. It is also possible. In the sixth embodiment, a method of diagnosing the corrosiveness of the installation environment of the outdoor unit will be introduced. In the sixth embodiment, the items not particularly described are the same as those of the first to fifth embodiments, and the same functions and configurations as those of the first to fifth embodiments are the same. It will be described using the code of.

When installing an outdoor unit in an area where the effect on aluminum-containing members installed in the outdoor unit is not known, the corrosiveness of the installation environment is determined by the presence or absence of corrosive substances already known in environmental surveys. Judging from the above, aluminum materials with a zinc sacrificial layer were used according to the environment. By installing the corrosion resistance diagnostic device 300 or the corrosion resistance diagnostic component 1 alone in the above area together with the outdoor unit, it is possible to grasp the influence on the aluminum-containing member provided in the outdoor unit.

Specifically, when the outdoor unit is installed, the corrosion resistance diagnostic device 300 or the corrosion resistance diagnostic component 1 alone is installed inside the outdoor unit. Then, after the operation of the air conditioner is started, the corrosion state of the corrosion resistance diagnostic component 1 is regularly investigated.

Specifically, one of the areas where the corrosiveness to the aluminum-containing member provided in the outdoor unit is known is set as the standard area. Then, data showing the relationship between the passage of time from the start of operation of the air conditioner in the standard area and the occurrence of local corrosion marks 5 on the exposed portion 3a of the corrosion resistance diagnostic component 1 is created. Then, when the outdoor unit is installed in a new area and the operation of the air conditioner is started, the occurrence condition of the local corrosion mark 5 of the exposed portion 3a of the corrosion resistance diagnostic component 1 installed inside the outdoor unit and the above-mentioned data. Compare with. This makes it possible to diagnose whether the corrosiveness of the new area where the outdoor unit is installed is larger or smaller than that of the standard area.

When the corrosion resistance diagnostic device 300 is installed inside the outdoor unit, the time elapsed from the start of operation of the air conditioner in the standard area and the occurrence of local corrosion marks 5 on the exposed portion 3a of the corrosion resistance diagnostic component 1. The data indicating the relationship is stored in the storage unit 314. Then, the comparison unit 315 compares the image data sent from the detection unit 313 with the data stored in the storage unit 314, and the corrosiveness of the new area where the outdoor unit is installed is the standard area. Diagnose whether it is larger or smaller than.

Further, data showing the relationship between the passage of time from the start of operation of the air conditioner in the standard area and the degree of corrosion progress of the first sacrificial layer 2 of the corrosion resistance diagnostic component 1 may be created. Then, when the outdoor unit is installed in a new area and the operation of the air conditioner is started, the corrosion resistance diagnostic component 1 installed inside the outdoor unit is brought back and the degree of corrosion progress of the first sacrificial layer 2 is measured. May be good. By comparing the measured degree of corrosion progress of the first sacrificial layer 2 with the above-mentioned data, the corrosiveness of the environment in which the outdoor unit is installed can be diagnosed with higher accuracy. The degree of corrosion progress of the first sacrificial layer 2 can be measured by the corrosion depth of the first sacrificial layer 2 described above.

As described above, the present invention may appropriately combine the configurations shown in the above embodiments. Further, the configurations shown in the above embodiments are merely examples, and do not limit the configurations of the present invention. In addition, the scope of the present invention is the scope indicated by the claims, and includes all modifications within the meaning and scope equivalent to the claims.

1 Corrosion resistance diagnostic parts, 2 1st sacrificial layer, 2a boundary, 3 1st core material, 3a exposed part, 4 liquid junction, 5 local corrosion marks, 6a 1st range, 6b 2nd range, 7 reference line, 7a reference point , 8 Corroded part, 9 Residual part, 10 Zinc residual area, 100 Outdoor heat exchanger, 200 Air conditioner, 201 Compressor, 202 Muffler, 203 Four-way valve, 204 Refrigerant piping, 205 Capillary tube, 206 Strainer, 207 Electronically controlled Expansion valve, 208a stop valve, 208b stop valve, 209 indoor heat exchanger, 210 auxiliary muffler, 211 controller, 300 corrosion resistance diagnostic device, 312 imaging unit, 313 detection unit, 314 storage unit, 315 comparison unit, 316 notification unit, 400 core part, 411 heat transfer tube, 412 fins, 413 exposed surface part, 414 fin contact part, 500 material for corrosion resistance diagnostic parts.

The present invention relates to a process for producing a corrosion resistance diagnostic components that are used in the diagnosis of corrosion status of the diagnostic material the sacrificial layer is formed containing zinc on the surface of the core material including aluminum, and diagnosis using the corrosion resistant diagnostic component Regarding the method.

The present invention has been made to solve the above-mentioned problems, and it is possible to more accurately diagnose the corrosion state of the material to be diagnosed in which a sacrificial layer containing zinc is formed on the surface of a core material containing aluminum. the method of manufacturing possible corrosion resistance diagnostic component, and a purpose thereof is to provide a diagnostic method using the corrosion diagnostic component.

The method for manufacturing a corrosion resistance diagnostic component according to the present invention is for an aluminum material having an arcuate radial cross section, extending in the axial length direction, and having zinc spraying and heat treatment applied to the radial outer periphery having an R portion. In a method for manufacturing a corrosion resistance diagnostic component for diagnosing the corrosion resistance of a heat exchanger having a flat tube as a heat transfer tube, a preparatory step for further preparing the other flat tube as the corrosion resistance diagnostic component and a radial cross section of the corrosion resistance diagnostic component. One of the surfaces subjected to the zinc spraying and the heat treatment facing the short axis direction is partially cut with respect to the axial length direction to form a flat portion, and one of the ones in the axial length direction. The radial cross section is connected to the first cutting step in which the aluminum material is exposed in the flat surface portion and the portion in which the aluminum material is exposed in the flat surface portion. The present invention includes a second cutting step of cutting both side surfaces facing each other in the axial length direction and exposing the aluminum material on both side surfaces .

Further, the diagnostic method according to the present invention is a diagnostic method for diagnosing the corrosion resistance of the heat exchanger using the corrosion resistance diagnostic component manufactured by the method for manufacturing the corrosion resistance diagnostic component according to the present invention, and exposes the aluminum material. On the surface of the flat surface portion, the range within a specified distance from the zinc sprayed portion is set as the first range, and when a local corrosion mark appears in the first range, the heat exchanger has reached the end of its life. Diagnose.

In the corrosion resistance diagnostic component manufactured by the method for manufacturing the corrosion resistance diagnostic component according to the present invention, one of the opposing surfaces of the surface subjected to zinc spraying and heat treatment is from the surface of the zinc sprayed portion to the zinc sprayed portion . The aluminum material is exposed by removing the inside of the aluminum material from the boundary with the aluminum material. That is, part fraction aluminum material of the corrosion diagnostic component is exposed, the boundary portion between the zinc thermal spraying unit and an aluminum material has been completely removed. In other words, part fraction aluminum material of the corrosion diagnostic component is exposed, the zinc diffused in the aluminum material is completely removed during the formation of the zinc spray unit. Therefore, in the corrosion diagnostic component, based on the corrosion status of parts of the surface where the aluminum material is exposed, it is possible to accurately diagnose than conventional corrosion status of the diagnostic material.

The method for manufacturing a corrosion resistance diagnostic component according to the present invention is for an aluminum material having an arcuate radial cross section, extending in the axial length direction, and having a R portion and being subjected to zinc spraying and heat treatment on the radial outer periphery. In a method for manufacturing a corrosion resistance diagnostic component for diagnosing the corrosion resistance of a heat exchanger having a flat tube as a heat transfer tube, a preparatory step for further preparing the other flat tube as the corrosion resistance diagnostic component and a radial cross section of the corrosion resistance diagnostic component. One of the surfaces subjected to the zinc spraying and the heat treatment, which faces the short axis direction of the above, is partially cut with respect to the axial length direction to form a flat portion, and one of the ones in the axial length direction. The rest not cut in the above is used as a zinc sprayed portion, and the first cutting step of exposing the aluminum material on the flat surface portion and the portion of the flat surface portion where the aluminum material is exposed are connected to the R portion. Both side surface portions of the radial cross section facing the axial length direction are cut so that both end surface portions of the corresponding radial cross section become a linear shape substantially parallel to the axial short direction, and the both side surface portions are formed. It includes a second cutting step for exposing the aluminum material.

Claims (19)

It is a corrosion resistance diagnostic component used for diagnosing the corrosion status of a material to be diagnosed in which a sacrificial layer containing zinc is formed on the surface of a core material containing aluminum.
The corrosion resistance diagnostic component is
The first core material containing aluminum and
A first sacrificial layer formed on the surface of the first core material and containing zinc having a lower corrosion resistance than the first core material.
With
In the corrosion resistance diagnostic component, at a position adjacent to the first sacrificial layer, the inner side of the first core material from the surface of the first sacrificial layer to the boundary between the first sacrificial layer and the first core material. Corrosion resistance diagnostic component in which an exposed portion is formed in which the first core material is exposed. On the surface of the exposed part,
When a local corrosion mark appears at a position adjacent to the first sacrificial layer, a first range in which the product using the material to be diagnosed is diagnosed as having a lifetime is arranged.
The corrosion resistance diagnosis according to claim 1, wherein a second range in which local corrosion marks appear prior to the first range is arranged at a position opposite to the first sacrificial layer with respect to the first range. parts. The first sacrificial layer is an aluminum-zinc alloy.
The corrosion resistance diagnostic component according to claim 1 or 2, wherein the first core material is an aluminum alloy containing no zinc. The corrosion resistance diagnostic component according to any one of claims 1 to 3.
An imaging unit that photographs the surface of the exposed portion,
From the image data taken by the photographing unit, a detection unit that detects a corrosion state on the surface of the exposed portion, and a detection unit.
Corrosion resistance diagnostic device equipped with. A storage unit that stores parameters indicating the corrosion status of the surface of the exposed portion,
A comparison unit that compares the detection result of the detection unit with the parameter stored in the storage unit,
A notification unit that notifies the comparison result of the comparison unit and
The corrosion resistance diagnostic apparatus according to claim 4. The corrosion resistance diagnostic device according to claim 5, wherein the parameter is associated with a corroded area of the first sacrificial layer in a cross section of the first sacrificial layer. The corrosion resistance diagnostic device according to claim 5, wherein the parameter is associated with the corrosion depth of the first sacrificial layer in the cross section of the first sacrificial layer. The corrosion resistance diagnostic device according to claim 5, wherein the parameter is associated with a weight change of the corrosion resistance diagnostic component. The corrosion resistance diagnostic component according to any one of claims 1 to 3.
A sacrificial layer containing zinc is formed on the surface of the core material containing aluminum, and the refrigerant piping through which the refrigerant flows,
With
The corrosion resistance diagnostic component is a heat exchanger formed of the same member as the refrigerant pipe. A heat transfer tube forming a part of the refrigerant pipe is provided.
The heat exchanger according to claim 9, wherein the corrosion resistance diagnostic component is made of the same member as the heat transfer tube. The corrosion resistance diagnostic device according to any one of claims 4 to 8.
A sacrificial layer containing zinc is formed on the surface of the core material containing aluminum, and the refrigerant piping through which the refrigerant flows,
With
The corrosion resistance diagnostic component is a heat exchanger formed of the same member as the refrigerant pipe. A heat transfer tube forming a part of the refrigerant pipe is provided.
The heat exchanger according to claim 11, wherein the corrosion resistance diagnostic component is made of the same member as the heat transfer tube. The corrosion resistance diagnostic component according to any one of claims 1 to 3.
A heat exchanger having a heat transfer tube in which a sacrificial layer containing zinc is formed on the surface of a core material containing aluminum,
A sacrificial layer containing zinc is formed on the surface of the core material containing aluminum, and a refrigerant pipe through which the refrigerant flowing into the heat exchanger or the refrigerant flowing out of the heat exchanger flows.
With
The corrosion resistance diagnostic component is an air conditioner formed of the same member as the refrigerant pipe. The corrosion resistance diagnostic device according to any one of claims 4 to 8.
A heat exchanger having a heat transfer tube in which a sacrificial layer containing zinc is formed on the surface of a core material containing aluminum,
A sacrificial layer containing zinc is formed on the surface of the core material containing aluminum, and a refrigerant pipe through which the refrigerant flowing into the heat exchanger or the refrigerant flowing out of the heat exchanger flows.
With
The corrosion resistance diagnostic component is an air conditioner formed of the same member as the refrigerant pipe. The method for manufacturing a corrosion-resistant diagnostic component according to any one of claims 1 to 3.
A preparatory step for preparing a material for a corrosion resistance diagnostic component in which the first sacrificial layer is formed on the surface of the first core material, and
From the surface of the first sacrificial layer, the inside of the first core material is removed from the boundary between the first sacrificial layer and the first core material, and the exposed portion is placed at a position adjacent to the first sacrificial layer. The forming process to form and
A method of manufacturing a corrosion-resistant diagnostic part equipped with. The preparatory step
The core material preparation step for preparing the first core material and
A sacrificial layer forming step of forming the first sacrificial layer on the surface of the first core material, and
The method for manufacturing a corrosion-resistant diagnostic component according to claim 15. The material for the corrosion resistance diagnostic part is plate-shaped and has a plate shape.
The forming step is
A first cutting step of cutting a flat surface portion of the material for a corrosion resistance diagnostic component and exposing the first core material on the flat surface portion.
A second cutting step in which both side surface portions of the corrosion resistance diagnostic component material are cut so as to be continuous with the exposed portion of the first core material in the flat surface portion, and the first core material is exposed on both side surface portions. ,
The method for manufacturing a corrosion-resistant diagnostic component according to claim 15 or 16. A diagnostic method for diagnosing the corrosion status of a material to be diagnosed in which a sacrificial layer containing zinc is formed on the surface of a core material containing aluminum by using the corrosion resistance diagnostic component according to any one of claims 1 to 3. There,
On the surface of the exposed portion, the range within a specified distance from the first sacrificial layer is defined as the first range.
A diagnostic method for diagnosing that a product using the material to be diagnosed has reached the end of its life when local corrosion marks appear in the first range. On the surface of the exposed portion, a range farther than the specified distance from the first sacrificial layer is defined as the second range.
The diagnostic method according to claim 18, wherein the remaining life of the product is diagnosed by the local corrosion marks appearing in the second range.

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