DESIGN & MANUFACTURING

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Each component must be properly cleaned prior to stacking to ensure a proper braze.  Once all the components are stacked and banded together, cores are vacuum brazed.

Cores are manufactured based on the available envelope space and requirements of each application.  External fins and internal fins are selected based on application data provided to ensure the maximum heat transfer and minimum pressure drop allowed.  Estimated performance of each core are calculated prior to manufacturing.

Data Required for Estimated Performance Calculations:

1.) Boost Pressure

2.) Boost Temperature

3.) Mass Air Flow

4.) Ambient Air Temperature

5.) Operating Altitude

6.) Ambient Air Flow

Cores are manufactured based on the available envelope space and requirements of each application.  External fins and internal fins are selected based on application data provided to ensure the maximum heat transfer and minimum pressure drop allowed.  Estimated performance of each core are calculated prior to manufacturing.

Data Required for Estimated Performance Calculations:

1.) Boost Pressure

2.) Boost Temperature

3.) Mass Air Flow

4.) Water Temperature

5.) Water Pump Pressure

6.) Water Pump Flow Rate

Before welding manifold to core, we recommend welding 4 places on the charge face / water side of the core to prevent infrequent leaks from developing.

General welding tips:

Use #4043 welding rod along with red tungsten electrode (2% thoriated) rather than green (pure), which is usually aluminum to achieve a more concentrated, narrow arc with less total heat put into the joint.

Good results may be achieved by using high amperage with a fairly linear travel.

Large rolls of aluminum material coils are fed through and stamped to create the fin requirements.

Each component is ultra sonic cleaned rigorously to remove any contaminants during manufacturing prior to brazing.

Vacuum brazing allows uniform brazing throughout the core with minimal contamination preventing core leakages & provides great weldability.

Heat exchanger systems are assembled on conveyor belts to customer's requirements.