WO2005097389A1 - Tuyau échangeur de chaleur, échangeur de chaleur, et procédé de fabrication de celui-ci - Google Patents

Tuyau échangeur de chaleur, échangeur de chaleur, et procédé de fabrication de celui-ci Download PDF

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Publication number
WO2005097389A1
WO2005097389A1 PCT/JP2005/007288 JP2005007288W WO2005097389A1 WO 2005097389 A1 WO2005097389 A1 WO 2005097389A1 JP 2005007288 W JP2005007288 W JP 2005007288W WO 2005097389 A1 WO2005097389 A1 WO 2005097389A1
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WO
WIPO (PCT)
Prior art keywords
spraying
thermal
heat exchanger
tube
recited
Prior art date
Application number
PCT/JP2005/007288
Other languages
English (en)
Inventor
Kazuhiko Minami
Tomoaki Yamanoi
Takenori Hashimoto
Original Assignee
Showa Denko K.K.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Showa Denko K.K. filed Critical Showa Denko K.K.
Priority to US11/547,796 priority Critical patent/US20090008068A1/en
Priority to DE112005000773T priority patent/DE112005000773T5/de
Publication of WO2005097389A1 publication Critical patent/WO2005097389A1/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
    • F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
    • F28F21/081—Heat exchange elements made from metals or metal alloys
    • F28F21/084—Heat exchange elements made from metals or metal alloys from aluminium or aluminium alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/0008—Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
    • B23K1/0012—Brazing heat exchangers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/008—Soldering within a furnace
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
    • F28D1/02—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
    • F28D1/04—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits
    • F28D1/053—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight
    • F28D1/0535—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight the conduits having a non-circular cross-section
    • F28D1/05366—Assemblies of conduits connected to common headers, e.g. core type radiators
    • F28D1/05391—Assemblies of conduits connected to common headers, e.g. core type radiators with multiple rows of conduits or with multi-channel conduits combined with a particular flow pattern, e.g. multi-row multi-stage radiators
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F1/00—Tubular elements; Assemblies of tubular elements
    • F28F1/10—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses
    • F28F1/12—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element
    • F28F1/126—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element consisting of zig-zag shaped fins
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F13/00—Arrangements for modifying heat-transfer, e.g. increasing, decreasing
    • F28F13/18—Arrangements for modifying heat-transfer, e.g. increasing, decreasing by applying coatings, e.g. radiation-absorbing, radiation-reflecting; by surface treatment, e.g. polishing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/04—Tubular or hollow articles
    • B23K2101/14—Heat exchangers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/28—Selection of soldering or welding materials proper with the principal constituent melting at less than 950 degrees C
    • B23K35/286—Al as the principal constituent

Definitions

  • the present invention relates to an aluminum heat exchanger usedfor, forexample, a refrigeration cycle for car air-conditioners , a tube for such heat exchangers, and a method of manufacturing the same.
  • aluminum denotes aluminum and its alloy.
  • Background Art The following description sets forth the inventozr' s knowledge of related art and problems therein and should not be construed as an admission of knowledge in the prior art.
  • the so-called multi-flow type or parallel flow type heat exchanger 51 as shown in Fig. 5 is we-ll-known.
  • a plurality of flat tubes 52 are arranged in the thickness direction with a corrugated fin 53 interposed therebetween, and hollow headers 54 are connected to the ends of the tubes 52 in fluid communication.
  • heat exchanger components are fabricated into a provisional assembly, and then the assembly is integrally brazed in a furnace .
  • Patent Document 1 Japanese Unexamined Laid-open Patent Publication No. S59-104657
  • brazing alloy is thermally sprayed onto a surface of an aluminum heat exchanger tube.
  • Patent document 2 JP,Hll-33709 ,A discloses a technique in which a brazing alloy is ttermally sprayed onto a streaked surface of a heat exchanger tubs (tube core) to thereby form a brazing layer.
  • Patent document 3 JP,H06-200344 ,A discloses a technique in which at the time of thermally spraying brazing alloy powder the brazing powder is thermally sprayed on a surface of a heat exchanger tube in a state in which non-fused structure remains partially without completely ffusing the alloy powder.
  • the preferred embodiments of the present invention have been developed in view of the above-mentioned and/or other problems, in the related art .
  • the preferred embodiments of the present invent ion can significantly improve upon existing methods and/or apparatus es .
  • the present invention was made in view of the aforementioned conventional technology, and aims to provide a heat exchanger be capable of preventingoccurrence of poorbrazing due to fin detachment or erosion of a tube by brazing material and attaining good brazi_ng, a heat exchanger and a method of manufacturing them.
  • the structure of the present invention can be summarized as follows .
  • Amethodofmanufacturing an aluminumheat exchanger tvxbe comprising the steps of: in forming a thermally sprayed layer on a surface of an alum-Lnum flat tube by thermally spraying Al-Si alloy thermal-sprayingr particles, quenching the thermally sprayed thermal-spraying particles in a molten state to make them adhere to the tube core; and smoothing a surface of the thermally sprayed layer to form a brazing layer.
  • the aluminumheat exchanger tube obtained by the manufacturing method of this invention will be combined with and brazed to, for example, an aluminum fin. At this time, good brazing performance can be secured.
  • the surface of the thermally sprayed layer formed by thermally spraying alloy is smoothed to obtain a brazing layer. Therefore, a fin can be joined in a balanced manner over the entire surface of the brazing layer, which assuredly prevents poor joining such as fin detachment. Furthermore, in this invention, since the thermally sprayed layer is smoothed to form the brazing layer, the smoothing enhances the brazing material filling rate of the brazing layer, resulting in a sufficient amount of the brazing material as the brazing layer, which can assuredly prevent poor brazing due to shortage of brazing material .
  • the thermally sprayed layer is formed into the brazing layer by smoothing the thermally sprayed layer, only the thermally sprayed layer can be assuredly formed into a desired state.
  • "melting" of the thermal-sprayingparticles can be performed by adjusting the thermal-spraying temperature to
  • thermal-spraying temperature is set to a high temperature
  • smoothing of the thermally sprayed layer can be executed effectively. That is, in the case of high temperature thermal spraying, it is considered that the thermal-spraying particles decrease in size, the cooling rate increases , the quickly cooled small sized thermal-spraying particles accumulate on the tube surface to form a desired brittle structure as the thermally sprayed layer, which enables effective smoothing of the thermally sprayed layer.
  • this invention by adjusting the temperature difference between the thermal-spraying particles in a molten state and the thermal-spraying particles reached the tube core in a cooled
  • thermal-spraying particles are cooled to 800 °C or below after reaching the tube core.
  • quenching of the thermal-sprayingparticles can be smoothly performed at the time of the thermal spraying.
  • a sufficient amount of the brazing material can be secured in the brazing layer, which in turn can assuredly prevent occurrence of brazing defects due to shortage of brazing material.
  • the method of manufacturing an aluminum heat exchanger tube as recited in any one of the aforementioned Items 1 to 9 wherein in thermally spraying the thermal-spraying particles, a thermal-spraying distance from a spraying position of the thermal-spraying particles to an adhering position on the tube core is adjusted to 30 to 150 mm. In this invention, quenching, etc., of thermal-spraying particles can be performed more assuredly.
  • a sacrificial protection layer can be formed on the tube surface.
  • a sacrificial protection layer can be formed on the tube surface, and the potential of the tube surface can also be adjusted.
  • a desired thermally sprayed layer can be formed assuredly in an efficient manner, which in turn can form a desired brazing layer assuredly and efficiently.
  • a method of manufacturing an aluminum heat exchanger tube comprising the steps of: in forming a thermally sprayed layer on a surface of an aluminum flat tube by thermally spraying Al-Si alloy thermal-spraying particles, thermally spraying the thermal-spraying particles to a tube core by an arc spraying method, and quenching the thermally
  • the brazing layer is obtained by smoothing the surface of the thermally sprayed layer obtained by the thermal spraying of brazing alloy.
  • the brazing layer is formed by smoothing the thermally sprayed layer, the smoothing can increase the brazing material filling rate of the brazing layer, a sufficient amount of brazing material in the brazing layer can be secured, which assuredly can prevent brazing defects due to shortage of brazing material.
  • molten thermal-spraying particles are thermally sprayed on the tube core by an arc spraying method and the sprayed thermal- spraying particles are quenched to a predetermined temperature or below.
  • a method of manufacturing an aluminum heat exchanger tube comprising the steps of: in forming a thermally sprayed layer on a surface of an aluminum flat tube by thermally spraying Al-Si alloy thermal-spraying particles , performing the thermal spraying by an arc spraying method in which a thermal-spraying distance from a spraying position of the thermal-spraying particles to an adhering position on the tube core is adjusted to 30 to 150 mm; and smoothing a surface of the thermally sprayed layer to form a brazing layer.
  • good brazing performance can be secured in the same manner as mentioned above.
  • thermo-spraying particles are thermally sprayed to the tube core by an arc spraying method, and the thermal-spraying particles are sprayed to tube core with high kinetic energy to thereby be deformed into a flat shape andquenched. Therefore, in the samemanner as in the abovementioned case, a heat exchanger tube of high quality can be secured.
  • a method of manufacturing an. aluminum heat exchanger tube comprising the steps of: in forming a thermally sprayed layer on a surface of an aluminum flat tube by thermally spraying Al-Si alloy thermal-spraying particles, thermally spraying the thermal-spraying particles with
  • a method of manufacturing an aluminum heat exchanger tube comprising the steps of: in forming a thermally sprayed layer on a surface of an aluminum flat tube by thermally spraying Al-Si alloy thermal-spraying particles, thermally spraying the thermal-spraying particles in a molten state and cooling to make them adhere to a tube core, and -adjusting a temperature difference between the thermal-spraying particles in a molten state and the thermal-spraying particles after
  • the cooling is adjusted to 2,500 °C or more; and smoothing a surface of the thermally sprayed layer to form a brazing layer.
  • the heat exchanger tube obtainedby the manufacturingmethod of this invention in the same manner as mentioned above, good brazing performance can be secured. Furthermore, in this invention, since molten thermal -spraying particles are sprayed to the tube core and the sprayed thermal-spraying particles are quenched, in the same manner as mentioned above, high quality heat exchanger tube can be provided.
  • An aluminum heat exchanger tube comprising: an aluminum flat tube core; and a thermally sprayed layer formed on a surface of the tube core by thermally spraying thermal-spraying particles of molten Al-Si alloy, wherein a surface of the thermally sprayed layer is smoothed to form a brazing layer, and wherein an average equivalent diameter of Si crystallization particles in the thermally sprayed layer is adjusted to 1 ⁇ m or less.
  • the brazing layer is formed by smoothing the thermally sprayed layer, in the same manner as mentioned above, good brazing performance can. be secured. Moreover, since the Sicrystallizationinthe thermallysprayed layer is small, it is possible to confirm the melting and quenching of the thermal-sprayingparticles at the time of the thermal spraying, and therefore a heat exchanger tube of high quality can be obtained.
  • An aluminum heat exchanger including a pair of aluminum headers and a plurality of heat exchanger tubes arranged in a longitudinal direction of the header with a fin interposed therebetween, end portions of the heat exchanger tubes being communicated with the headers, wherein the heat exchanger tubes are manufacturedby themethod as recited in any one of the aforementioned Items 1 to 23.
  • This invention specifies the so-called parallel-flow type or multi-flow type heat exchanger equipped with the heat exchanger tubes obtained by the aforementioned manufacturing method of the invention as main components. Therefore, in the same manner as mentioned above, the same functions and results can be secured.
  • a method of manufacturing an aluminum heat exchanger comprising: a step of preparing an aluminum heat exchanger tube manufacturedby themethod as reci ed in any one of the aforementioned Items 1 to 23; a step of preparing an aluminum fin; and a step of brazing the heat exchanger tube and the fin in an assembled state.
  • the heat exchanger is manufactured using the heat exchanger tube ohtained by the aforementioned manufacturingmethodof the invent ion, in the samemanner asmentioned above, the same functions and results can be secured.
  • a method of manufacturing an aluminum heat exchanger comprising: a step of preparing a plurality of aluminum heat exchanger tubes manufactured by the method as recited in any one of the aforementioned Items 1 to 23; a step of preparing a plurality of aluminum fins; a step of preparing a pair of headers _; a step of obtaining a provisional assembly in which the plurality of heat exchanger tubes arranged in a longitudinal direction of the header with the fin interposed therebetween are assembled with the headers with end portions odE each heat exchanging tube communicated with the headers ; a step of integrally brazing adjacent heat exchanger tubes and the fins by simultaneously brazing the provisional assembly.
  • Fig. 1 is a front view showing an aluminum heat exchanger according to an embodiment of this invention
  • Fig.2 is an enlarged perspective view showing joined portions of the tubes and fins in the heat exchanger of the aforementioned embodiment
  • Fig. 3A is an enlarged cross-sectional view showing a tube core immediately after thermal spraying during a manufacturing process of the heat exchanger tube according to the embodiment
  • Fig. 3B is an enlarged cross-sectional view showing the tube core immediately after smoothing of the thermally sprayed brazing material
  • Fig. 1 is a front view showing an aluminum heat exchanger according to an embodiment of this invention
  • Fig.2 is an enlarged perspective view showing joined portions of the tubes and fins in the heat exchanger of the aforementioned embodiment
  • Fig. 3A is an enlarged cross-sectional view showing a tube core immediately after thermal spraying during a manufacturing process of the heat exchanger tube according to the embodiment
  • Fig. 3B is an enlarged cross-sectional view showing the tube core immediately after smoothing of the thermally
  • FIG. 4A is an enlarged cross-sectional view showing a tube core immediately after thermal spraying in a manufacturing process of the heat exchanger tube, which is an example outside the scope of the invention
  • Fig. 4B is an enlarged cross-sectional view showing the tube core immediately after smoothing of the tube core
  • Fig. 5 is a front view showing a conventional heat exchanger in which fin detachment occurred due to braz ing.
  • FIG. 1 is a front view showing an aluminum heat exchanger 1 which is an embodiment of this invention. As shown in this figure, this heat exchanger 1 is used as a condenser for use in a refrigeration cycle of a car air-conditioner, and constitutes a multi-flow type heat exchanger. In this heat exchanger 1 , a plurality of flat heat exchanging tubes 2 arrangedhorizontally are disposed between a pair of vertical hollow headers 4 and 4 arranged in parallel with each other with the ends of the tubes communicated with the hollow headers 4 and
  • a corrugated fin 3 is disposed, and a side plate 10 is disposed outside the outermost corrugated fin 3.
  • brazing material is covered on predetermined portions of each component.
  • the tube 2 includes a tube core 2a which is an aluminum extruded member and a brazing layer 20 of an Al-Si alloy as brazing alloy formed on at least one surface of the tube core.
  • a brazing layer 20 of an Al-Si alloy as brazing alloy formed on at least one surface of the tube core.
  • an Al-Mn alloy with Ixigh pressure resistance (high strength) andhighheat resistance, suclias a JIS3003 alloy can be preferably used.
  • the tube core can be preferably used as the core 2a of the tube 2 preferably used.
  • the surface roughness Ry of the tube core 2a is adjusted to less than 10 ⁇ m. That is, if the surface roughness Ryexceeds 10 ⁇ m, capillaryattraction occurs on the surface of the tube core 2a, resulting in easy flow of brazing material, which in turn causes erosion to the tube by the brazing material.
  • the brazing layer 20 on the tube core 2a is formed by forming a thermally sprayed layer 21 by making Al-Si alloy adhere to the tube core by a thermal spraying method as shown in Fig. 3A, and then smoothing the surface of the thermally sprayed layer 21 by compressing the surface as shown in Fig. 3B.
  • a method of carrying out tb_ermal spraying of the Al-Si alloy as a brazing alloy to the surface of the tube core 2a is not limited to a specific one, in performing the thermal spraying, the thermal-spraying particles are sprayed to the tube core 2a andquenched.
  • the thermal spraying method of this invention is not specifically limited so long as the aforementioned quenching can be performed. In this embodiment, in order to melt the thermal-sp aying
  • the thermal-spraying temperature can be set to 3,000 °C or above, or any known means including a means using arc spraying can be adopted.
  • a means for quenching the thermal-spraying particles for example, it is preferable to employ a method in which the thermal-spraying temperature of the brazing alloy at the time of thermal spraying is adjusted to high, the hot thermal-spraying particles are sprayed on the tube core 2a, and the heat of: the thermal-spraying particles is made to emit to the tube core 2a immediately after the reaching of the thermal-spraying particles to the core member 2a to thereby quickly cool the thermal-spraying particles to a temperature of the tube core member 2a.
  • a means for cooling the thermal-spraying particles whose
  • thermal-spraying temperature is 3,000 °C or above to 800 °C or below by making them adhere the tube core 2a can be employed.
  • thermal-spraying temperature is high (4,500 to 5,500 °C) to the tube
  • thermal-spraying particles are low (2,000 to 3,000 °C) as compared with arc spraying, there are possibilities that melting of the thermal-spraying particles cannot fully be performed, or increasing of the cooling rate is difficult and therefore quenching cannot fully be performed. Furthermore, since they use brazing alloy powder, there is a possibility that the filling rate may deteriorate and therefore it is not always suitable. In this invention, however, if quenching can be performed irrespective of the thermal-spraying temperature and/or the tube core temperature, anykindof thermal sprayingmethodcanbe employed. For example, the quenching of the thermal-spraying particles can be performed by controlling the thermal-spraying distance which will be explained below.
  • the thermal-spraying distance from the spraying portion (spraying position) of the thermal spraying gun to the tube core surface (adhering position) it is preferable to adjust the thermal-spraying distance from the spraying portion (spraying position) of the thermal spraying gun to the tube core surface (adhering position) to 30 to 150 mm. That is, in cases where the thermal-spraying distance is within the aforementioned specified range, the speed of thermal-spraying particles is high. and therefore the kinetic energy of the thermal-spraying particles is high. For this reason, since the thermal sprayingparticles change into a flat shape and adhere to the tube core surface when the thermal spraying particles are sprayed on the tube core surface, the filling rate becomes high and the heat release performance of the thermal spraying particles to the tube core 2a is also improved, which enables sufficient quenching.
  • the thermal-spraying distance is relatively short, i.e., 30 to 150 mm, resulting in a shorter arriving time of the thermal-spraying particles to the tube core 2a, or a shorter time from the thermal-spraying of the thermal-spraying particles to the cooling initiation, which in turn can perform the quenching more assuredly.
  • the thermal-spraying distance is less than 30 mm or exceeds 150 mm, the speed of the thermal-spraying particles becomes slower and therefore sufficient kinetic energy cannot be secured, causing a smaller amount of deformation of the thermal-spraying particles when the thermal-spraying particles adhere to the tube core, resulting in low filling rate.
  • the heat releasing performance of the thermal-spraying particles to the tube core deteriorates, resulting in a failure of quenching.
  • the thermal-spraying distance exceeds 150 mm
  • the thermal-spraying particles different in flying speed may aggregate.
  • large particles and small particles will aggregate to become large particles to be deposited.
  • the thermally sprayed layer 21 becomes hard and moderate brittleness cannot be secured.
  • smoothing of the thermally sprayed layer 21 cannot be attained effectively, and therefore it is not preferable .
  • a brazing alloy is sprayed by an arc spraying method
  • a method of scanning a thermal spraying gun of an arc spraying machine with respect to the tube core 2a or a method of carrying out thermal spraying while rewinding the core member 2a rolled into a coiled form can be adopted.
  • the tube core 2a is an extruded member
  • a method in which extrusion and thermal spraying are performed continuously while placing a thermal spraying gun arranged immediately after an extrusiondie canbeemployed. Especiallyincaseswhereextrusion and thermal spraying are performed continuously, productive efficiency can be improved.
  • thermal spraying processing in order to prevent the formation of an oxide film on thermal-spraying particles, it is preferable to perform the thermal spraying processing in a non-oxidizing atmosphere, such as a nitrogen atmosphere or an argon atmosphere. From the economical view point, it is preferable to perform the thermal spraying in a nitrogen atmosphere.
  • the thermally sprayed layer 21 can be formed only on one surface of the tube core 2a, and also can be formed on both surfaces .
  • the thermally sprayed layer 21 is formed on both surfaces of the tube core, it is preferable to arrange thermal spraying guns at upper and lower sides of the tube core 2a.
  • the content of Si in the thermally sprayed layer 21 is not specifically limited, in order to secure good brazing performance, it is preferable to adjust the Si content to 6 to 15 mass %.
  • the thermally sprayed layer 21 contains Zn in order to form a sacrificial protection layer on the surface of the tube.
  • the Zn content in the thermally sprayed layer 21 is preferably adjusted to 1 to 30 mass %.
  • the thermally sprayed layer 21 contains Cu within the range of 0.1 to 1 mass % for the purpose of potential adjustment, etc. Furthermore, in this embodiment, the thermally sprayed layer 21 may contain other elements, such as Fe, Mn, In, Sn, Ni, Ti, and Cr, as long as it is within the range that affects neither brazing performance nor corrosion resistance.
  • the thermally sprayed layer 21 after forming a thermally sprayed layer 21 on the tube core 2a as shown in Fig.3A, the surface of the thermally sprayed layer 21 is smoothed to form a brazing layer 20 as shown in Fig. 3B. Thus, a heat exchanger tube 2 is obtained.
  • the method of smoothing the surface of the thermally sprayed layer 2 is not specifically limited, a pressing method using reduction rolls and a cutting method such as scalping (trimming) can be exemplified.
  • a method of smoothing using reduction rolls is preferably employed since the method can improve the productivity by consecutive operation. This smoothing processing is preferably performed at the tube correcting step.
  • the surface roughness Ry of the smoothed brazing layer 20 is preferably adjusted to 50 ⁇ m or less, more preferably to 40 ⁇ m or less. That is, in cases where the surface roughness falls within the specified range, the fin 3 can be brazed to the brazing layer 20 in a balanced manner, which can prevent occurrence of brazing defects such as fin detachment.
  • the thermal-spraying particles are sprayed in a molten state and then quenched at the aforementioned thermal spraying processing, moderate brittleness can be given to the thermally sprayed layer 21. Therefore, as shown in Fig.
  • the crushing of the brittle peak portions of the thermally sprayed layer 21 can be evenly performed over the entire region with rollers , etc.
  • the surface of the thermally sprayed layer 21 (surface of the brazing layer) can be assuredly formed to have a desired smooth surface .
  • the volume rate (filling rate) of the brazing material in the entire brazing layer (apparent brazing layer) containing voids can be improved, resulting in a sufficient amount of brazing material on the tube required to perform brazing.
  • the filling rate of the brazing material in the brazing layer 20 is preferably adjusted to 40% or more, more preferably 60% or more.
  • the tube core 2a having the thermally sprayed layer 121 of high rigidity is rolled with reduction rollers , as shown in this Fig.4B, the tube core 2a is deformed without causing any deformation of the thermally sprayed layer 121, which may cause deteriorated quality. Furthermore, since the thermally sprayed layer 121 is not compressed, the filling rate of the brazing material in the thermally sprayed layer 121 cannot be improved, which may make it difficult to secure the necessary amount of brazing material required for brazing. In this embodiment , it is preferable to adjust the average equivalent diameter of the Si crystallization in the brazing layer 20 to 1 ⁇ m or less.
  • the particle diameter of Si crystallization is preferable small. Concretely, it is preferable to adjust the average equivalent diameter of Si crystallization to 1 ⁇ m or less. Althoughthethickness (average thickness) of thebrazinglayer 20 is not specifically limited, it is preferable to adjust the thickness to 3 to 50 ⁇ m.
  • the lower limit is adjusted to 5 ⁇ m or more and the upper limit to 30 ⁇ m or less. That is, in cases where the thiclcness of the brazing layer 20 is adjusted within the aforementioned range, the joining of the tube 2 and the fin 3 can be performed assuredly, and fin detachment, etc., can be prevented effectively.
  • the heat exchanger tube 2 of this embodiment is used together with other heat exchanger components, such as hollow headers 4 and 4, corrugated fins 3 and side plates 10, and is assembled into a provisional heat exchanger assembly. Thereafter, flux is applied to this assembly and dried. Then, the assembly is heated in a furnace of a nitrogen gas atmosphere to thereby integrally braze the components. Thus, a heat exchanger 1 is manufactured.
  • the obtained heat exchanger 1 is free from brazing defects such as fin detachment, and is excellent in joined strength. That is , in the heat exchanger tube 2 of this embodiment , since the brazing layer 20 is obtained by smoothing the surface of the thermally sprayed layer 21 formed by the thermal spraying of brazing alloy, the fin 3 can be joined to the entire surface of the brazing layer 20 in a balanced manner, which in turn can assuredly prevent brazing defects such as fin detachment. Especially in this embodiment, if the surface roughness Ry of the tube core 2a is adjusted to less than 10 ⁇ m, the brazing layer 20 is secured to the entire surface of the tube core 2a in a stablemanner.
  • the brazing layer 20 is formed by compressing the thermally sprayed layer 21, the brazing material filling rate of the brazing layer 20 can be improved. Therefore, sufficient amount of brazing material for the brazing layer 20 can be secured, which can assuredly prevent occurrence of brazing defects due to shortage of brazing material. Furthermore, in this embodiment, since fully molten thermal spraying particles are quenched, moderate brittleness can be given to the thermally sprayed layer 21.
  • the thermally sprayed layer 21 can be compressed into a desired compressed shape.
  • crush deformation of the tube core 2a can be prevented effectively, resulting in high quality.
  • the fin 3 in cases where the surface roughness Ry of the brazing layer 20 is adjusted to below the specific value, the fin 3 can be brazed to the brazing layer 20 in a balanced manner, which can more assuredly prevent occurrence of brazing defects such a fin detachmen .
  • Example 1> As shown in Table 1, a flat multi-bored extruded tube (tube core) 16mm width, 3 mm height and 0.5 mm wall thickness was extruded with an extruder using extrusion material of an Al alloy (Cu: 0.4 mass%, Mn: 0.21 mass%; Al: balance). The surface roughness Ry of the obtained tube core was 10 ⁇ m. An Al-Si alloy was thermally sprayed to the upper and lower surfaces of the extruded tube through thermal spraying guns of an arc spraying machine arranged at the upper and lower sides of the outlet of the extruder, to thereby form a thermally sprayed layer.
  • an Al-Si alloy was thermally sprayed to the upper and lower surfaces of the extruded tube through thermal spraying guns of an arc spraying machine arranged at the upper and lower sides of the outlet of the extruder, to thereby form a thermally sprayed layer.
  • the thermal-spraying distance was adjusted to 120 mm in the atmosphere.
  • Table 1 as for the cooling degree of the thermal-spraying particles, in cases where the difference between the thermal-spraying temperature of the thermal-spraying particles and the temperature of the tube core was 2 , 500 °C or more, it was denoted as "quenching", and in cases where it was less than 2,500 °C, it was denoted as "non-quenching.
  • Example 1 the thermal-spraying temperature of the thermal-spraying particles was 5,000 °C, the temperature of the tube core was 400 °C, and those temperaturedifferencewas 4 , 600 °C . Accordingly, the cooling degree in Example was quenching. After performing the thermal spraying, the aforementioned extruded tube with a thermally sprayed layerwas immersed in a cooling bath to be cooled, and then continuously rolled into a coil form.
  • the coil formed tube was pressed with reduction rollers to compress the thermally sprayed layer to smooth the surface, thereby forming a brazing layer 50% in net filling rate of the brazing material (apparent filling rate of the brazing material to the brazing layer), 20 ⁇ m in thickness, and 40 ⁇ m in surface roughness (Ry) , and then cut into a predetermined length to obtain heat exchanger tubes .
  • the average equivalent diameter of Si rystallization was 0.7 ⁇ m.
  • T"hen using the aforementioned heat exchanger tubes, the so-called multi-flow type aluminum heat exchanger (see Fig. 1) was provisionally assembled.
  • Example 2 A.s shown in table 1 , against the extruded tube 8 ⁇ m in surface roughness Ry, thermal spraying was performed by an arc spraying method at the thermal-spraying temperature of 5,500 °C and the thermal-spraying distance of 60 mm in a nitrogen atmosphere. The tube member with the thermally sprayed layer was pressed with reduction rollers to form a brazing layer 50% in brazing material filling rate, 15 ⁇ m in thickness, 37 ⁇ m in surface roughness Ry. Thus , the heat exchanger tube was manufactured in the same manner as mentioned above. In this tube, the average equivalent diameter of Si crystallization was 0.1 ⁇ m. Then, a heat exchanger was manufactured using the heat exchanger tubes in the same manner as in the aforementioned Example.
  • Example 3 As shown in table 1 , against the extruded tube 7 ⁇ m in surface roughness Ry, thermal spraying was performed by an arc spraying method at the thermal-spraying temperature of 4,800 °C and the thermal-spraying distance of 60 mm in a nitrogen atmosphere. The tube member with the thermally sprayed layer was pressed with reduction rollers to form a brazing layer 60% in brazing material filling rate, 20 ⁇ m in thickness, 35 ⁇ m in surface roughness Ry. Thus , the heat exchanger tube was manufactured in the same manner as mentioned above. In this tube, the average equivalent diameter of Si crystallization was 0.5 ⁇ m. Then, a heat exchanger was manufactured using the heat exchanger tubes in the same manner as in the aforementioned Example.
  • Example 5 As shown in table 1, against the extruded tube 8 ⁇ m in surface roughness Ry, thermal spraying was performed by an arc spraying method at the thermal-spraying temperature of 4,800 °C and the thermal-spraying distance of 120 mm in a nitrogen atmosphere. The tube member with the thermally sprayed layer was pressed with reduction rollers to form a brazing layer 40% in brazing material filling rate, 20 ⁇ m in thickness, 40 ⁇ m in surface roughness Ry. Thus, the heat exchanger tube was manufactured in the same manner as mentioned above. In this tube, the average equivalent diameter of Si crystallization was 0.8 ⁇ m. Then, a heat exchanger was manufactured using the heat exchanger tubes in the same manner as in the aforementioned Example.
  • Example 6> As shown in table 1, against the extruded tube 8 ⁇ m in surface roughness Ry, thermal spraying was performed by an arc spraying method at the thermal-spraying temperature of 5,000 °C and the thermal-spraying distance of 100 mm in a nitrogen atmosphere. The tube member with the thermally sprayed layer was pressed with reduction rollers to form a brazing layer 50% in brazing material filling rate, 25 ⁇ m in thickness, 42 ⁇ m in surface roughness Ry. Thus , the heat exchanger tube was manufactured in the same manner as mentioned above. In this tube, the average equivalent diameter of Si crystallization was 0.6 ⁇ m. Then, a heat exchanger was manufactured using the heat exchanger tubes in the same manner as in the aforementioned Example .
  • This invention can be applied to an aluminum heat exchanger for use in a car air-conditioning refrigeration cycle, a heat exchanger tube used for such a heat exchanger, an-d a manufacturing method thereof . While the present invention may be embodied in many different forms, a number of illustrative embodiments are described herein with theunderstanding that the present disclosureis to be considered as providing examples of the principles of the invention and such examples are not intended to limit the invention to preferred embodiments described herein and/or illustrate---- herein.
  • the term "preferably” is non- exclusive andmeans “preferably, but not limited to.”
  • means-plus-function or step-plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation: a) "means for” or “step for” is expresslyrecited; b) a corresponding function is expressly recited; and c) structure, material or acts that support that structure are not recited.
  • the terminology "present invention” or “invention” may be used as a reference to one or more aspect within the present disclosure.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Geometry (AREA)
  • Coating By Spraying Or Casting (AREA)

Abstract

Cette invention concerne un procédé de fabrication d'un tuyau échangeur de chaleur en aluminium. En formant une couche thermiquement pulvérisée 21 sur la surface d'un tuyau d'aluminium horizontal par pulvérisation thermique de particules d'alliage Al-Si, en trempant les particules thermiquement pulvérisées à l’état fondu pour les faire adhérer au corps du tube 2a. La surface de la couche thermiquement pulvérisée 21 est lissée avec, par exemple, des laminoirs pour former une couche de brasure 20. Avec ce procédé, les défauts de brasure dus au détachement des bavures, à l'érosion sur le tuyau du matériau de brasure, etc., peuvent être évités, ce qui permet de bonnes performances de brasure.
PCT/JP2005/007288 2004-04-08 2005-04-08 Tuyau échangeur de chaleur, échangeur de chaleur, et procédé de fabrication de celui-ci WO2005097389A1 (fr)

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US11/547,796 US20090008068A1 (en) 2004-04-08 2005-04-08 Heat Exchanger Tube, Heat Exchanger, and Manufacturing Method Thereof
DE112005000773T DE112005000773T5 (de) 2004-04-08 2005-04-08 Wärmetauscher-Rohr, Wärmetauscher und Verfahren zum Herstellen derselben

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Cited By (3)

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FR2915694A1 (fr) * 2007-05-03 2008-11-07 Air Liquide Procede ameliore de brasage d'aluminium a pression atmospherique
US7989087B2 (en) * 2006-06-30 2011-08-02 Sumitomo Light Metal Industries Brazing fin material for heat exchangers, heat exchanger, and method of manufacturing same
US20180056363A1 (en) * 2016-08-24 2018-03-01 Toyota Jidosha Kabushiki Kaisha Method for producing heat sink

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EP2289687A1 (fr) 2007-05-16 2011-03-02 Entex Rust & Mitschke GmbH Procédé de traitement de produits de dégazage
KR20100091471A (ko) * 2009-02-10 2010-08-19 엘에스전선 주식회사 자동차 열교환기용 압출 튜브 및 이의 제조 방법
NL2010441C2 (en) * 2013-03-12 2014-09-16 Dejatech Ges B V Combined heat and power (chp) system.
CN103940153B (zh) * 2014-04-10 2016-08-17 美的集团股份有限公司 平行流换热器、空调机
EP3561434B1 (fr) * 2016-12-21 2023-03-29 Mitsubishi Electric Corporation Échangeur de chaleur, son procédé de fabrication, et dispositif à cycle frigorifique
CN112760459A (zh) * 2020-12-30 2021-05-07 宜兴市鼎锋模具制造有限公司 高速钢工具及其加钨方法

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JPH06172959A (ja) * 1992-11-05 1994-06-21 Mitsubishi Alum Co Ltd 熱交換器用アルミニウム偏平管の製造方法
JPH07124787A (ja) * 1993-10-29 1995-05-16 Showa Alum Corp ろう付用アルミニウム材料の製造方法
JPH10251824A (ja) * 1997-03-17 1998-09-22 Furukawa Electric Co Ltd:The 溶射用Ａｌ合金粉末ろう材とその溶射方法及びこれによって得られるろう材被覆押出多穴偏平チューブ
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JPH06172959A (ja) * 1992-11-05 1994-06-21 Mitsubishi Alum Co Ltd 熱交換器用アルミニウム偏平管の製造方法
JPH07124787A (ja) * 1993-10-29 1995-05-16 Showa Alum Corp ろう付用アルミニウム材料の製造方法
JPH10251824A (ja) * 1997-03-17 1998-09-22 Furukawa Electric Co Ltd:The 溶射用Ａｌ合金粉末ろう材とその溶射方法及びこれによって得られるろう材被覆押出多穴偏平チューブ
JPH1133709A (ja) * 1997-07-16 1999-02-09 Furukawa Electric Co Ltd:The アルミニウム合金製チューブ及び熱交換器

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Publication number Priority date Publication date Assignee Title
US7989087B2 (en) * 2006-06-30 2011-08-02 Sumitomo Light Metal Industries Brazing fin material for heat exchangers, heat exchanger, and method of manufacturing same
FR2915694A1 (fr) * 2007-05-03 2008-11-07 Air Liquide Procede ameliore de brasage d'aluminium a pression atmospherique
WO2008148986A2 (fr) * 2007-05-03 2008-12-11 Centre Regional D'innovation Et De Transfert De Technologie Pour La Transformation Et Le Traitement Des Metaux Et Alliages (Critt) Procede ameliore de brasage d'aluminium a pression atmospherique
WO2008148986A3 (fr) * 2007-05-03 2009-02-26 Ct Regional D Innovation Et De Procede ameliore de brasage d'aluminium a pression atmospherique
US20180056363A1 (en) * 2016-08-24 2018-03-01 Toyota Jidosha Kabushiki Kaisha Method for producing heat sink
US10596618B2 (en) * 2016-08-24 2020-03-24 Toyota Jidosha Kabushiki Kaisha Method for producing heat sink

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