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specialty-cuprobraze

CuproBraze Technology

CuproBraze heat exchangers are made using special anneal-resistant alloys of copper and brass. Tubes are fabricated from brass strip and coated with a brazing filler material. The copper fins, coated tubes, headers and side-supports made of brass are fitted together into a core assembly, which is then brazed in a furnace.
processscheme

Many small, mid-size and high-volume production facilities are making CuproBraze heat exchangers for OEMs and the aftermarket since year 2000. So called one-shot brazing entered production scale in 2008.

CuproBraze technology is flexible and scalable. The International Copper Association licenses CuproBraze technology free of charge to heat exchanger manufacturers. Technical experts of the member companies of CuproBraze Alliance will assist you in transferring the technology to your production line anywhere in the world.

Tubes -Start with the Tubes

Process description

coatedtubes
Coated radiator tubes

The most common method for making tubes is HF-welding. Special machinery forms the brass strip into tubes. The edges of the strip are then welded together and the welded tube cut to length in the same machine. Welded CuproBraze tubes can also be purchased.
A typical radiator tube has cross sectional dimensions of about 16 x 2 mm and wall thickness 118 to 152 µm, depending on application.

The external surfaces of both the radiator tubes and CAC tubes are then sprayed with brazing paste and dried.

ca-cinnerfinandfoil

Charge air cooler tubes are bigger. The cross sectional area is typically 60 x 6 mm and wall thickness 200 µm. In addition, internal turbulators formed of copper strip are inserted, together with brazing foil, which forms the joints between the turbulators and the inner walls of the tubes during brazing CAC tube with inner turbulators. Brazing foil inserted between the turbulators and inner tube wall.

High or medium volume

weldingline
Tube welding machine
tube-coating-bc
Tube coating machine
tubessprayed
Tube coating machine

Low volume

tube-low1For low volume production it makes sense to buy tubes. Tube coating can be done manually with a simple HVLP-spraygun. The tubes are dried with warm air blowing.
tube-low2A simple tool can be used for inserting turbulators and the brazing foil into the CAC tubes.

Fins- Bring in the Fins

Process description

Copper fins are essential to the operation of advanced heat exchangers. Their high thermal conductivity and great strength allow for the fabrication of much thinner fins than aluminum. A variety of fin designs can be fabricated depending on the application. The fins are cut to length and collected for assembly. The fin thicknesses start from 32 µm.

High or medium volume

fin-machine1Fin machine

Low volume

fin-machine2Fin machine is needed for all volumes of production.

Next Step Is Core Assembly

Process description

core-assembly
Core Assembly

Typically, a heat-exchanger core is made from fins, tubes, header plates and side supports. Folded fins are inserted between the tubes.

The tube ends of the tube-fin assemblies must be inserted into holes in the header plates. These plates hold the entire assembly together.

High or medium volume

core-assembly1A semi-automatic core builder

Low volume

tube-low2.1Core building table

Header Paste Application

Process description

A crucial step in the entire manufacturing process is the application of the brazing paste around the holes in the header plates. The quality of the tube-to-header joint plays a pivotal role in the longevity of the heat exchangers.

A long service life depends on uniform coverage of the joint on the header plate with the paste that contains the brazing alloy.

High or medium volume

header-paste-application1Header paste application machine

Low volume

header-paste-application2Header paste can be applied manually simply from a squeeze bottle and dried with warm air blowing.

Brazing Furnace

Process description

The heart of the CuproBraze production line is the furnace. This is where heat-exchanger cores are brazed in a nitrogen atmosphere.

There are several types and sizes of furnaces available, depending on the part sizes and volume of production.

A CuproBraze brazing furnace is fitted with a forced nitrogen convection-cooling section to cool the parts to 150°C. Nitrogen convection cooling gives the product a bright appearance and allows the overall length of the furnace to be shorter.

High or medium volume

brazing-furnace1A three-chamber furnace with a double in-out operating mode is ideal for a medium-size production line and increases productivity because it allows for more efficient use of the middle (brazing) chamber, where the holding time is the shortest.

For high-volume production, the best choice is a continuous furnace, in which heat exchangers are loaded onto a moving belt.

A typical high-volume production furnace is sized for brazing at rates of 1500 kg/h with a 1200 mm wide belt and a 350 mm pass height throughout the furnace. An automated control system allows for flexibility when brazing parts of different configuration and mass.

Low volume

brazing-furnace2A single chamber batch furnace meets the needs of a small production volume

CuproBraze is Flexible and Scalable

A major advantage of the CuproBraze process is its flexibility. A wide variety of products can be processed on the same production line.

A worldwide network of materials suppliers and equipment makers stands ready to guide you, whether you plan to build a high-volume CuproBraze production facility or purchase CuproBraze heat exchangers from an Alliance member. For more detailed information about the CuproBraze process and the key factors for good results, please download the CuproBraze Brazing Handbook.

Key Factors for Good Results

  • Use clean parts.
  • Apply correct amount of filler metal.
  • Do not overheat paste during drying.
  • Use suitable fixturing during brazing.
  • Check that the oxygen content is less than 20 ppm in the furnace.
  • Apply correct brazing temperature on the parts

The contents of these items are explained in more details in the Handbook.

 

More Information about the Technology:

  • CuproBraze Brazing Handbook
  • Technical Literature
  • Video
  • News Releases

    • Reduction of Fan Power in Comparison to Plate and Bar Type Aluminum Heat Exchangers
    • Cuprobraze Attending Aimex Exhibition
    • Young Touchstone Leverages Benefits of Copper/Brass Brazing for Heavy-Duty Markets
    • Bombardier Achieves Superior Performance at a Lower Initial Cost
    • Blogs from 2011 – 2014 By Markku Ainali & Juho Partanen
  • Technical-Links

    • Definition of CuproBraze
    • CuproBraze Technology
    • CuproBraze Brochure
    • CuproBraze Brazing Handbook
    • CuproBraze Alliance
    • Alliance Literature
    • Upcoming Events
  • Testimonials

    The advantages of CuproBraze over other heat exchanger technologies were clearly evident from the beginning.
    Jorge Warnholtz Plant ManagerClimex World
    CuproBraze is the technology of choice for future generations of heat exchangers.
    Jan AnderssonProject LeaderRabe Consulting
    We have successfully tested cooling systems with our customers and are now experiencing the initial waves of demand for CuproBraze.
    Mike SprengerDirector of Sales & Marketing, Young Touchstone. ER 55
    The more familiar we become with brazed copper-brass, the more we like it.
    Jack ChisenhallPresidentVintage Air
    As a brazing process, CuproBraze can make heat exchangers that are inherently more durable than soldered copper-brass and also superior to aluminum products.
    Randolph SinghChairman and Managing DirectorGS Radiators
    Using CuproBraze technology, we can offer superior and cost-effective products.
    - Sunil Haridass, DirectorDeccan Radiators & Pressings, Ltd.
    Clearly, it is superior to any prior technology. We firmly believe that eventually all charge air coolers will be made of copper and brass using the CuproBraze process.
    Hannu VetikkoManaging DirectorFinnish Radiator Manufacturing Company
    It is a milestone for Nanning Baling Technology to become the first company in China to mass produce CuproBraze heat exchangers.
    Gu Yu, General ManagerNanning Bailing Technology
    After our specialists attended several seminars and visited SHAAZ’n new plant, it was obvious that CuproBraze was exactly what we needed.
    Alexander Vedernikov Manager of Technical DevelopmentURAL
    We closely examined the CuproBraze technology and its implications for our markets. Our customers indicated that they would be interested in CuproBraze products if we could make them.
    James E. CornwellVP of ManufacturingRADAC

Latest news

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    Reduction of Fan Power in Comparison to Plate and Bar T ...

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    Cuprobraze Attending Aimex Exhibition ...

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    Young Touchstone Leverages Benefits of Copper/Brass Bra ...

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