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Aluminum Brazing Presentation Utilizing Magnetic Field Controllers


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Aluminum Brazing Presentation Utilizing Magnetic Field Controllers

  1. 1. Computer Assisted Induction Aluminum BrazingR. C. Goldstein, V. S. Nemkov, R. T. Ruffini Centre for Induction Technology, Inc. 1
  2. 2. Overview• Automotive Heat Exchangers• Pipe to Tube Brazing• Computer Simulation of Induction Brazing of Pipe to Tube Joints• Optimization of Induction Coil• Conclusions 2
  3. 3. Automotive Heat Exchangers• Used for thermal management in many areas of the car – Oil Coolers – Powertrain – Air Conditioning – Dehumidifiers – etc. 3
  4. 4. Heat Exchanger Manufacturing• Assembling of heat exchanger bodies• Brazing of body in a controlled atmosphere furnace• Attachment of various components for connection to different cars – Nylon tanks – Aluminum pipes with connection blocks (most common) 4
  5. 5. Pipe to Tube Brazing• Clamshell Inductors – Problems with electrical contacts – Complicated mechanical design• “Horseshoe-Hairpin” Inductors – Non-uniform heating in circumference – Complicated magnetic field distribution 5
  6. 6. Pipe to Tube Induction Brazing Installation using “Horseshoe-Hairpin” Coil Connection Block Pipe Joint Fluxtrol A Magnetic Flux Controller Copper Coil Tube Header Body 6
  7. 7. Computer Simulation of Pipe to Tube Brazing• Not possible to simulate all processes due to process complexity• 2-D approach can not be used for Horseshoe-Hairpin inductors• 3-D electromagnetic simulation used to study heat sources (most controllable factor) 7
  8. 8. 1/4 of a Heat Exchanger Brazing Coil Pipe Tube Fluxtrol A Magnetic Flux Controller Copper Coil Heat Exchanger Header 8
  9. 9. Main Variables in this System• Coil and Concentrator Dimensions• Coil Position• Contact in the Brazing Joint• Coil Crossover 9
  10. 10. Different Crossovers+ + + .. . . + 10
  11. 11. Existing Induction Coil with Diagonal CrossoverNo Contact Good Contact 11
  12. 12. Existing Induction Coil with Horizontal CrossoverNo Contact Good Contact 12
  13. 13. Current Density Distribution for Optimized Induction Coil 13
  14. 14. New Induction Coil 14
  15. 15. Conclusions• Induction aluminum brazing of heat exchanger joints can be a very complicated process• 3-D computer electromagnetic simulation provided good information regarding the heating process• Optimized induction coil and process was more robust and produced higher quality joints• Further study should be made using 3-D coupled electromagnetic plus thermal simulation 15