Aluminium Condenser Header Pipe

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Aluminium Condenser Header Pipe

Aluminum header pipe is made from clad aluminum alloy strip shaped into an open circular tube by a welded tube forming machine, and then prepared by high frequency welding.

Aluminum condenser header pipe, also called aluminum condenser manifold, is one of the essential components in HVAC system. Its function is to evenly distribute the flow path of coolant in the air cooler, dry cooler, evaporator and condenser to avoid temperature layers in the pipeline airflow through which the coolant passes.

The manifold consists of an oversized pipe that ensures that the coolant flows through with such a small and uniform velocity and pressure that it has a negligible effect on the inlet resistance of the individual circuits.

The fluorine in the air conditioner is compressed by the compressor to produce a high-temperature, high-pressure liquefied gas, which is condensed by the condenser and becomes a low-temperature, high-pressure liquid that enters the header pipe.

Technical Specifications

Cladding

Singel-layer cladding,
Double-layers cladding

Cladding Alloy

4045, 4343, 7072 anti-corrosion layers,
Zinc painted available

Temper

H14, H16, H18 & customized acceptable

Cladding Ratio

8-10%±2 & customized acceptable

Core Layer

1060, 3A21, 3003, 3305, 6063, etc.

Processing

High-frequency welding

Dimension

Wall thickness

1.0-3.0mm

OD

4.0-61mm

Aluminium Condenser Header Pipe2

Capacity

Annual Production Capacity

4 Welded Tubing lines —— 4,000 Ton

Manufacturing Capabilities

Welding
Folding
Stamping / Punching
Off-line Cutting

Additional Capabilities

Consultative design assistance
Consultative materials selection

R&D Solutions

High corrosion resistance Aluminum material development

Development of various types of D type manifold

Development of square header pipe

Production View

DANIELI Extruder

DANIELI Extruder(ITALY)

IAS induction Heater

IAS induction Heater (Germany)

Skaltek Winder

Skaltek Winder(Sweden)

Metallisation arcspray system

Metallisation arcspray system(UK)

TAIYO Cutter

TAIYO Cutter(Japan)

MORI induction welder

MORI induction welder

The causes and solutions of weld leakage of Aluminium Condenser Header Pipe.

Condenser is a kind of equipment that can condense gaseous substances into liquid state, which is widely used in automobile air conditioner and household air conditioner, etc. It is composed of two parts: collector tube and fins.
Controlling the leakage rate of aluminum alloy for condenser in line with high-frequency welded tubes to zero has been the goal of all parties, including aluminum strip suppliers, aluminum welded tube producers and condenser manufacturers. However, feedback about condenser manifold leakage continues to come back from the industry. We analyze the causes of condenser manifold leakage from the perspective of condenser manifold producers and propose solutions for your reference in anticipation of further reducing the condenser manifold leakage rate.

Condenser manifold weld leakage pattern.Statistics show that 99.8% of the leakage points of condenser manifolds are concentrated in the weld area, and there are three main manifestations of weld leakage: porosity leakage, micro-crack leakage and slag leakage.

Pore leakage refers to the leakage in the weld area when the test pressure has not yet reached the specified value.

Micro crack leakage.

Observation of the microstructure of the condenser collector tube weld can be returned, the crack atmosphere through the two categories of cracks and local micro cracks.

Micro cracks in the weld through the tube wall

Micro cracks in the weld through the tube wall

Micro crack in the middle of the weld

Micro crack in the middle of the weld

Inclusion leakage refers to the presence of metal oxides or non-metal oxides, such as Al2O3, SiO2, etc., in the weld seam of the condenser manifold, which are not related to the aluminum alloy organization.

Condenser manifold weld leakage causes.

Longitudinal shearing of aluminum tube strips with irregular cut surfaces.

Longitudinal shearing of aluminum tube strips with irregular cut surfaces.

The guide ring for forming rolls is not designed for the characteristics of aluminum tube strips.

The guide ring for forming rolls is not designed for the characteristics of aluminum tube strips.

Improper control of welding process parameters.

Solutions to prevent condenser manifold weld leakage

Optimization of aluminum strip slitting process

Optimizing the design of guide rings for aluminum tube forming rolls

Optimization of welding process parameters

Optimization of welded pipe adjustment specification

The depth of weld seam of HF welded square header pipe.

The weld seam includes the fusion line and the heat affected zone, in fact, the so-called weld seam depth is related to the skin effect of high frequency current and the squeezing pressure.

The skin effect depends on the frequency of the high-frequency welding machine, and the squeezing pressure depends on the unit extrusion roll.

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