Brazing Handbook

BRAZING HANDBOOK
Edition #9, November 2009

Luvata Sweden AB

2
Forewords

The CuproBraze brazing Handbook is a tool to share the latest knowledge
on the CuproBraze technology, gathered within Luvata, International
Copper Association and the member companies of CuproBraze Alliance.
CuproBraze process has been in commercial operation since year 2000.
There are numerous plants running around the world and more are under
construction.
This book is updated every 2 to 3 years. The principal change to the
previous edition is that the book is focusing on established and dominant
technologies. Future technologies are introduced under Ongoing
development.
All guidelines and recommendations in this book should be seen as advices.
Sometimes better, or other as good ways to success can be found, which is
fascinating for the user of the process.
Recent achievements include:
- A Low-Cost CuproBraze line concept has been introduced 2007, based on
established technology.
- One-shot brazing has entered mass production in 2008.
After 10 years of mass production, the CuproBraze technology still has an
enormous new development potential for the next 30 years.
Vsters, Sweden, October 19, 2009.

Markku Ainali
Editor in Chief
Contact: [email protected]

Editorial team: Peter Morsing, Anders Falken, Henrik Larsson, Robbie Robinson

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Contents
1. General
1.1 Efficient heat exchangers
1.2 Technology development
1.3 Effects of annealing
1.4 Soldering and brazing
2. Copper alloys
2.1 Fin material
2.2 Tube material
2.3 Brass material for headers, side supports and tanks
2.4 Strength at elevated operating temperatures
3. Filler materials
3.1 Brazing powder
3.2 Brazing foil
3.3 Brazing paste
4. Paste application
4.1 Paste on tubes
4.2 Paste on fin tips
4.3 Tube-to-header joints
5. Fabrication and assembly of components
5.1 Tubes
5.2 Fins
5.3 Headers
5.4 Surface conditions
5.5 Brazing fixtures and assemblies

4
6. Brazing operation
6.1 Atmosphere
6.2 Temperature and time
7. Selecting a furnace
7.1 Batch furnace
7.2 Semi-continuous furnace
7.3 Continuous furnace
7.4 Heating source

8. Process emissions
9. Corrosion resistance
9.1 Cleaning after brazing
9.2 lnternal corrosion
9.3 External corrosion
9.4 Coatings

10. Special brazing processes
10.1 One shot brazing
10.2 Brazing of parts with internal turbulators (CAC)
10.3 Brazing of steel parts

11 Quality control
11.1 Quality control before brazing
11.2 Visual inspection after brazing
11.3 Visual inspection of the tube-fin joints after cutting of the fin
11.4 Cross sections of the joints

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12. Reparability
12.1 Soldering
12.2 Re-brazing
12.3 Brazing with AgCu filler metals

13. Troubleshooting

14. Getting started
14.1 Contacts
14.2 More information

15. Ongoing development

16. CuproBraze in brief

References

Disclaimer

CuproBraze Alliance members

1. General


6

II I III
CuproBraze
Brazed Soldered
Aluminium Copper/Brass

7
1. General

The CuproBraze process was specifically developed for the
manufacture of heavy-duty mobile and industrial heat exchangers.
The word CuproBraze is trademarked and owned by ICA
International Copper Association.
New brass and copper alloys offer high strength as well as excellent
retention of strength at elevated operating temperatures. They can
withstand high-temperature brazing processes without substantial
loss in strength. The fin alloy SM0502, tube alloy SM2385 and
brazing alloy OKC600 have been developed and patented by Luvata.
A Brazing Centre was established by Luvata to support the
technology in a practical way - to build prototype heat exchangers
based on these new alloys and to demonstrate the CuproBraze
process. The Centre is located in Finspong, Sweden. As a result,
CuproBraze technology is now being applied globally in the
manufacture of advanced heat exchangers using the new brazing
process described in this book.
Specialized brazing alloy application machinery and brazing furnaces
are available for all capacities of production lines. This Handbook
provides an update on CuproBraze brazing technology in use today.
It details trends in the selection of furnaces, the application of filler
materials, the assembly of components and the control of brazing
operations. By using high-strength and high-conductivity copper
alloys, it is possible to manufacture strong, efficient and compact
heat exchangers at a competitive cost with an environmentally
friendly process.

8


The high thermal conductivity and high strength of new copper and
brass alloys have changed the rules of design for mobile heat
exchangers.
The new brass-tube and copper-fin alloys offer high strength as well
as excellent retention of strength at elevated operating temperatures.
They make copper and brass extremely attractive, once again, for
heat exchangers of all shapes and sizes, like mobile radiators,
heaters, oil coolers and charge air coolers.
In recent years, designers have demanded lighter fins and tubes and
hence stronger alloys for more-compact, and higher-efficiency heat
exchangers. An important advantage of thin gauge material is that,
besides reducing weight, the lower cross-sectional area allows air to
pass more freely through the core of the heat exchanger. The relative
ease with which air flows through a radiator core is measured as a
lower air pressure drop for a given performance. A low air pressure
drop is highly desirable in advanced design of efficient compact heat
exchangers for fuel-efficient vehicles. Less fan power means also
less noise.


The use of thin gauges in compact heat exchangers requires new
processes. The International Copper Association responded to the
industry need for a new generation of copper-brass radiators by

9
developing CuproBraze technology, which is now being applied
globally in the manufacture of advanced heat exchangers.
CuproBraze technology was specifically developed for application to
automotive and heavy-duty industrial heat exchangers. For example,
it enables the manufacture of charge air coolers that can withstand
higher temperatures than existing equipment, allowing the
transportation industry to continue reducing emissions and increasing
fuel efficiency by providing and option to the temperature-
challenged aluminum charge air coolers.


The alloys used in conventional copper and brass radiators are
designed for soldering below 450 C. When subjected to higher
temperatures for long periods, these conventional alloys, soften due
to annealing - a well understood metallurgical effect. Annealing
rearranges the positions of metal atoms in the metal lattice through
solid-state diffusion effectively removing the deformations that
would otherwise strengthen the alloys. The resulting decrease in the
yield strength is particularly steep for metals previously strengthened
by rolling or other deformation-hardening processes.
Annealing is time and temperature dependent. Because annealing is
based on solid-state diffusion, metals and alloys can significantly
lose strength well below the melting point; however, annealing is
much more pronounced at temperatures close to the melting point.
Process engineers and radiator designers have long been confronted
with an either-or type of dilemma. Brazing processes promised
strong bonds at the joints but brazing weakened the bulk material
because of softening. Heat-exchanger designers have been frustrated
for several decades by these limitations. The industry had to wait for

the development of anneal-resistant copper alloys before further
advances could be made.
As an example, figure 1 shows the softening properties for
conventional copper for fins and the CuproBraze copper for fins.

Figure 1. Example of softening properties for fin copper for
soft soldering (standard fin copper) and CuproBraze.


For decades, manufacturers have avoided annealing effects in
copper-brass radiators by using solders that melt well below
annealing temperatures. These solders are used to bond copper fins to
brass tubes and brass tubes to headers, which are the essential steps
in radiator assembly. These methods are still widely employed today
to make heavy-duty radiators for truck and off-road applications. A
10

11
tremendous body of specialized manufacturing expertise and process
knowledge that also includes many specialized machines and
furnaces have been developed around this industry. The basic
process consists of melting, flowing and solidifying the solder at the
joint, typically forming a metallic bond with the soldered surfaces (or
parent metals).
Soldering and brazing involve the same bonding mechanism except
that soldering is defined as using filler metals that melt below 450 C
and brazing uses filler metals that melt above this temperature. In
both soldering and brazing the bonding mechanism is a reaction
between the filler metal and the parent metal or metals. Brazing and
soldering usually result in alloying, i.e., a metallic-type bond forms
at the interface.
Typically, the filler metal flows into the joint gap by capillary force,
solidifies and forms a bond. The capillary force is dependent on the
gap clearance, which means that the filler metal flows rather into a
narrower than a wider gap. Oxides and contamination of the surface
adversely affect the capillary force. Several factors play a role in the
mechanical performance of the finished joint. For example, joint
clearance and geometry are important. In general, the joint strength is
higher for narrow joints. Other effects of the geometry are the
possibilities of slag entrapment and void formation in the joint.
Interactions between the filler metal and the base metal take place in
both soldering and brazing. Because of the higher temperatures the
interactions are usually greater for brazing than soldering. The
interactions are time and temperature dependent. To minimize
interactions, the brazing temperature should be as low as possible,
and the time period that the materials are held at the brazing
temperature should be as short as possible. For more detailed
information regarding soldering and brazing in general, see
references 8, 9 and 10.

2. Copper alloys for CuproBraze

2.1 Fin material

2.2 Tube material


2.4 Strength at elevated temperatures

12

13
2. Copper alloys for CuproBraze

Conventional deformation-hardened alloys soften when exposed to
brazing temperatures. Fortunately, researchers faced this challenge
and developed strong materials that could withstand the brazing
temperatures and remain strong. Anneal resistant copper alloys are
strengthened by mechanisms other than merely deformation
hardening.
In this Handbook the basics for the materials for CuproBraze are
described. The fin material, tube material and brazing powder alloy
have been developed and patented by Luvata. The material data is for
information only and not for use as purchase specification. Consult
the material manufacturers directly as regards valid material
specifications.

2.1 Fin material
The material designation of this anneal resistant patented copper is
SM0502, CuCr0.2. The basic alloying element is thus chromium.
The mechanism of the alloying is that it forms copper-chromium
intermetallic compounds. During the casting operation most of the
chromium is dissolved in the copper matrix. Before the final rolling
procedure the material is annealed and some of the precipitates will
be dissolved. In this state there is a lot of chromium in solid solution,
with the consequence that the electrical conductivity is much lower
than for conventional copper. The electrical conductivity at this stage
is around 60 % IACS. Heat conductivity is proportional to the
electrical conductivity. The material is delivered to customers in this
condition. After the fins have been formed and assembled with the
tubes and headers to a core, brazing is done in a furnace. The brazing
process can be regarded as the last heat treatment for this copper

14
alloy. During brazing the chromium in the solid solution precipitates
out of solution from the copper matrix. The precipitates that have the
greatest effect in preventing softening are 2 nanometers (0.000002
mm) in diameter. The result is a material that now exhibits an
electrical conductivity of 90 % IACS and with the retained strength.
The most commonly used material temper for corrugated fins is
called standard temper. For more complicated fins, like turbulators
inside charge air cooler tubes, copper in soft temper is recommended,
table 1.

Table 1. Nominal mechanical properties of copper fin material
SM0502 for CuproBraze.The figures after brazing also depend on
the type of brazing cycle.
Temper 47B
(standard temper)
Temper 79B
(soft temper)
Properties Unit
Before
brazing
After
brazing
Before
brazing
After
brazing
Conductivity % IACS 60 90 min
93 typ.
60 90 min
93 typ.
Yield
strength
N/mm
2

300

200 min
260 typ.

100-

140 min
165 typ.

Tensile
strength
N/mm
2

330-410

300 min
330 typ.
255-
315
270 min
295 typ.
Hardness HV 110-130 100 typ. 65-85 80 typ.
Elongation
A
50
% 1- 6 min
12 typ.
10-*
20-**
10 min
23 typ.
Temper 47B: thickness 0.032 - 0.30 mm, width 5.0 324 mm
Temper 79B: * thickness 0.040 - 0.060 mm, width 5.0 324 mm
** thickness 0.061 - 0.28 mm, width 5.0 324 mm
typ. =typical values (on temper 47B for thicknesses <0.1 mm)

15
This new fin material must not be used to make conventional
soldered radiators, because soldering temperatures are not high
enough to raise the thermal conductivity. It should only be used for
the manufacture of CuproBraze heat exchangers. The CuproBraze
brazing operation is needed to restore the thermal conductivity.
Additional physical properties for copper fin material are listed in
table 5.
Figures 2 and 3 show the softening of the copper fin material for
CuproBraze at different holding (brazing) times and temperatures.
The tables are useful in estimating the base material strengths after
different brazing temperatures and times. There can be differences in
the melting temperatures of brazing alloys based on type (paste, foil,
etc).

Figure 2. Yield and tensile stresses for fin copper SM0502, standard
temper 47B, at different temperatures and holding times.
16

Figure 3. Yield and tensile stresses for fin copper SM0502, soft
temper 79B, at different temperatures and holding times.

The material strength curves for different temperatures and times
(Fig. 2, 3, 6 and 7) are useful also in estimating base material
strengths after brazing, if brazing temperature or time is changed for
some reason.
17

2.2 Tube material

The conventional brass that is used for radiator tubes is of
composition 65 -70 % copper and 30-35 % zinc. The brass alloy that
has been developed and patented for higher temperature joining
purposes is called SM2385, ASTM/UNS C66420 basically a brass
composed of 85 % copper and 14 % zinc, i.e. CuZn14Fe0.9. Figure 4
compares the yield strength for conventional 10/70 brass and the
anneal resistant brass. To achieve anneal resistance, a mechanism
had to be introduced in the material to avoid re-crystallization. The
principle that is utilized in this alloy, too, is the use of precipitates
that prevent the material to re-crystallize. The brass is, therefore,
alloyed with about 1 % of iron.

Figure 4. Comparison of SM1070 standard brass with the anneal
resistant SM2385 brass.
18

19
The iron forms particles that are about 0.2 m in size. That fact, in
combination with a very small grain size gives a very high resistance
to re-crystallization. Nominal mechanical properties for brass tube
materials, before and after brazing, are listed in table 2. Additional
physical properties for the tube material are listed in table 3.
The basic contribution to softening resistance is the fine grain size
coupled with the grain size retention even after being subjected to
temperatures as high as 670 C. The grain size of the base material is
adjusted to 3 m (0.003 mm).

Table 2. Nominal mechanical properties of brass tube material
SM2385 for CuproBraze.The figures after brazing also depend on
the type of brazing cycle.

Tube brass
SM2385, C66420 (CuZn14Fe0.9)
Properties Unit
Before brazing

After brazing
Conductivity %IACS 35 30
Yield strength N/mm
2
288-430 270
Tensile strength N/mm
2
386-490 400
Hardness HV 115-145 125
Elongation A
50
% 17-38 30-
Thickness 0.090 2.0 mm, width 5.0 600 mm

When using the tube material for HF-welding, note the differences in
melting temperatures and melting ranges (A and B) compared with
conventional tube brass. See figure 5 and table 3.

Table 3. Nominal melting properties for tube brasses.
Brass alloy Melting
range
C
T
solidus
C

T
liquidus
C
SM1070 (conventional) 40 920 960
SM2385 (CuproBraze) 15 1010 1025

Figure 5. The binary phase diagram copper-zinc showing the
differences in melting temperatures and melting range between
conventional tube brass 70/30 (SM1070, dashed lines) and the
CuproBraze tube alloy (SM2385, solid lines).

This means that higher energy input and more precise temperature
control in the welding are needed when welding CuproBraze brass.
In figure 6 the softening properties in form of the yield and tensile
stresses at different temperature and holding times are shown.
20

Figure 6. Yield and tensile stresses for tube brass SM2385 at
different temperatures and holding times.

21

22

The header brass material is called SM2464, C74400 with
composition Cu64ZnNi3. It was originally developed for lamp socket
production requiring multiple forming processes. The material
exhibits excellent formability and good mechanical properties even
at elevated temperatures. The alloy is solution hardened by the nickel
addition and that accounts for the retained mechanical properties
after the brazing operation.
The mechanical data before and after the brazing process are shown
in table 4.

Table 4. Nominal mechanical properties of brass header, side
support and tank material SM2464.The figures after brazing also
depend on the type of brazing cycle.

Header material
SM 2464, C74400 (Cu64ZnNi3)
Properties Unit
Before brazing After brazing

Yield strength N/mm
2
101-143 105
Tensile strength N/mm
2
334-389 340
Hardness HV 61-82 67
Elongation A
50
% 49-76 75
Thickness 0.090 2.0 mm, width 5.0 600 mm

In figure 7 the softening properties for the yield and tensile stresses
at different temperature and holding times are shown

Figure 7. Yield and tensile stresses for header brass SM2464 at
different temperatures and holding times.

The physical properties of the header brass together with other
CuproBraze alloys are summarized in table 5.
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24

Table 5 - Nominal physical properties of copper and brass materials
for CuproBraze.
Physical
properties
Unit Fin copper
SM0502
Tube brass
SM2385, C66420
Header
SM2464,
C74400
Density kg/m
3

8900

8750

8500

Melting
temperature
C

1083

1010 - 1025

>910

Specific heat kJ /kgC

0.385

0.380

0.377

Thermal
expansion
20-300C
C
-1

17.7x10
-6

19x10
-6

19x10
-6

Youngs modulus
of elasticity
MPa

118 000

128 000

103 400

2.4 Strength at elevated operating temperatures

Besides being anneal resistant, the new copper-fin and brass-tube
alloys have high strength at elevated temperatures. For example,
when the operating temperature is increased from 0 C to 300 C the
tensile strength of the brass-tube alloy only decreases from 400
N/mm
2
to 260 N/mm
2
, and the tensile strength for copper-fin alloy
only decreases from 350 N/mm
2
to 260 N/mm
2
. Similarly, the fin and
tube alloys retain much of their yield strength at 300 C.
Figure 8 illustrates the strength at the specific temperature from room
temperature to 300 C for the two alloys.

New generations of charge air coolers need to operate at
temperatures around 300 C. The copper fins and brass tubes
described here are well suited for such high-temperature service.

Figure 8. Tensile strength (R
m
) and yield strength (R
p
) of fin copper
SM0502 and tube brass SM2385 materials for CuproBraze
at
elevated operating temperatures.
25

3. Filler materials

3.1 Brazing paste
3.2 Brazing foil

Powder
OKC 600 + Binder = Paste
26

27
3. Filler materials

On the market, there are many well-known filler metals for
conventional brazing of copper and brass. Figure 9 shows melting
ranges of some brazing-alloy families.
Cu-P alloys together with one or more other metals are a group of
well known brazing materials for copper and copper alloys. A widely
used brazing alloy for copper is CuP6 alloy. The melting range for
this alloy is 707 850 C and could not be used for CuproBraze.
Additions of silver and zinc in the CuP alloys decrease the melting
point but still the temperatures are too high. Silver is also too
expensive to be used as alloying element for mass production of heat
exchangers.
Except for the CuSnNiP-family, no other filler metals have so far
been found to be suitable for the CuproBraze process in mass
production scale. The brazing filler metals used for joining
CuproBraze fins and tubes belong to the lower temperature end of
the CuSnNiP-family. Table 6 lists the composition of the brazing
alloys that are used in the CuproBraze process.
OKC600 alloy is patented by Luvata (U.S. Patent #5,378,294) but
can be freely used for automotive and heavy-duty industrial heat
exchanger applications. This alloy is used for brazing powder.
Alloy VZ 2255 from Vacuumschmelze is mainly used for brazing
foil but can also be used as brazing powder.

Figure 9. Brazing alloy families and melting ranges.

Table 6. Nominal composition of CuproBraze filler metals.
Brazing
alloy
Copper,
Cu%
Nickel,
Ni%
Tin,
Sn%
Phosphorus,
P%
Melting
range
C
OKC 600 Balance 4.2 15.6 5.3 600 - 610
VZ 2255 Balance 7.0 9.3 6.5 600 - 630

Heat exchanger manufacturers do not normally handle powder. They
purchase readily made paste which is a mixture of brazing powder,
binder, solvent and some additives.
Cold forming of the filler metals shown in table 6 is virtually
impossible. It means that roll bonding (often called cladding) of the
filler metal on the tube or fin material is not possible. OKC600 filler
metal alloy is available as powder, which can be mixed into brazing-
pastes.
28

The powder is produced by gas atomizing the molten material into
spherically shaped, fine-grained powder. Atomization is normally
performed in protective gas such as nitrogen. The atomization
parameters are set for a maximal particle size of about 90 m.
Depending on the powder manufacturer, the average particle size is
normally 15 m to 30 m. In practice, each atomized lot is passed
through a sieve to exclude particles exceeding 90 m in diameter.
Figure 10 shows a typical powder size distribution.

Figure 10. Typical particle size distribution and shape of OKC600
brazing powder.

The fresh atomized powder is very sensitive to oxidation. Therefore,
some powder manufacturers reduce (Reduction is the reverse
chemical reaction to oxidation) the powder to remove surface
oxidation. The powder must be protected against oxidation and
humidity during manufacturing, transportation and storing. The
product data sheets and storing instructions should be carefully
followed. In case the powder oxidizes during transport or storage,
reconditioning by reduction treatment might be possible by powder
manufacturers.
29

30
3.1 Brazing paste

To make it possible to apply the brazing powder for brazing of the
cores, it is mixed with a binder to a suitable brazing paste. The binder
is mostly specific for each paste manufacturer, which means that
pastes from different manufacturers should not be mixed together.
Application can then be done by means of conventional commercial
paste application methods, like spraying, brushing, rolling etc.
The binder is a chemical or a mixture of chemicals and is specific for
each paste manufacturer. The binders can contain quite different
kinds of chemical groups which mean that mixing of pastes with
different kinds of binders can destroy the application and/or the
brazing properties. The binders should decompose or evaporate
cleanly below the brazing temperature and without leaving residues
on the brazed samples. The binders are also chosen to be
environmentally friendly.
All pastes are premixed and are ready to use after stirring. The
stirring recommendations from the paste manufacturer should be
followed in order to secure good paste applicability. There are pastes
with different viscosities to be used at different kinds of joints, as
well as different application methods. Contact the paste manufacturer
to use the right kind of paste.
There are two main types of binder systems, solvent-based and
thermoplastic. The solvent-based binders are dissolved in a solvent.
The solvent is evaporated during drying, leaving a hard binder and if
the binder is mixed with brazing powder, it will give a hard coating
after drying which only could be re-dissolved in a solvent.
The pastes have normally long shelf life. For detailed information
regarding the paste properties, contact the paste manufacturer.

31
_______________________________________________________
Important
Do not make a mixture of pastes from different manufacturers, as
they may not use the same binder system.

3.2 Brazing foil

In some cases, the brazing foil can be more practical than paste and
should be considered as an alternative or complementary brazing
material to the paste - depending on the process requirements, heat
exchanger design and production volume. Especially for brazing
inner fins or turbulators to tubes for charge air coolers and oil coolers
and for multi-tube radiator designs the foil could be considered as an
alternative brazing material.
A fully metallic brazing foil (VZ2255) with a thickness from 20 m
to 40 m is available for the CuproBraze process. The foil is made in
one process step to the final dimension by a rapid solidification
process. Due to the amorphous structure the brazing foil is
completely ductile meaning it can be bent during application without
breaking.
The brazing result and joint properties of the foil will be the same as
for OKC600 based powder/paste. Brazing foil and brazing paste can
be combined in one brazing procedure in the same heat exchanger.
The foil (figure 11) is available in the widths of 15-115 mm and a
thickness of 20-40 m.

Figure 11. Brazing foil VZ2255 in different foil widths and
application for brazing of turbulators inside CAC-tube.

32

33
. Paste application
4.1 Paste on tubes

ints

4

4.3 Tube-to-header jo

34
. Paste application
to form joints between the tubes and the fins
s well as to join the tubes to the header. Tank to header and other
e is normally applied on the tube
rfaces, see figure 12
Figure 12. Paste applied as tube coating
4

Brazing pastes are used
a
kinds of joints can also be brazed

or tube-to-fin joints, brazing past F
su

35
A layer of paste can be applied on the surfaces of the heat exchanger
parts by many different methods, such as spraying, dipping, roll
coating etc.
The paste has to be dried, normally with warm air. Good temperature
control during heating and drying is needed to prevent overheating
and subsequently poor brazing results. The brazing properties of the
paste can be destroyed above 130 C. Instructions from paste
suppliers must be followed.
Most of the brazing pastes involve some kind of solvent, which can
form effluents during drying. Contact the paste-manufacturer for
more information.
_______________________________________________________
Important
Do not overheat the paste during drying.

4.1 Paste on tubes

4.1.1 Spraying
The method most commonly used today is spraying paste with
commercial spray guns. As an example, tube coating, manually as
well as automatic spraying is illustrated in figures 13 and 14. It is
now possible to have the spray coating in-line with the tube welding
equipment without turning the tube direction. Alternatively, by
turning the tubes 90, it is possible to lower the coating speed and
work off-line.

36
As pastes can have different spraying properties as well as drying
time, the settings of the applying parameters sometimes have to be
changed.
The coating is not a homogenous brazing metal; instead it is formed
with particles and binder and after drying can also be porous, which
means that the coating thickness for a certain weight could differ
from spraying methods as well as type of paste. Therefore the
amount of brazing metal should be measured as weight/surface area.
Coatings should be evenly applied with a dry coating weight of 150-
250 g/m
2
. Formula [1] shows a calculation of the amount of paste on
tubes related to these values. Table 7 shows the amount of paste
related to some tube dimensions. The better the tolerances of the
tubes and fins, the thinner the layer can be (cost saving issue). It is
recommended to start from the thickest (heaviest) end and gradually
optimize downwards as long as the brazing result is good.

A =L x 2(H +W) x P [1], where

A: the amount of dried paste on the tube
L: the length of the tube
H: the height of the tube
W: the width of the tube
P: the preferred amount of paste/m
2

Table7. Recommended amount of paste for some tube dimensions.
Tube Dimensions
mm
Amount of paste
g/m
2
Amount of dried
paste g/m tube
16x2 150 5.4
16x2 250 9.0
19x2 150 6.3
19x2 250 10.5
40x4 150 13.2
40x4 250 22
60x6 150 25.8
60x6 250 43

Pastes which have a high metal content and which leave a smooth
surface after drying are preferred.
It is easier to achieve correct gap widths in tube/header joints if tube
ends are left uncoated. However, experience has shown that tight
tube/header seams can be achieved both with uncoated and coated
tube ends.

Figure 13. Manual tube spraying of charge air cooler tubes.
37

Figure 14. Automatic spraying of paste on radiator tubes. Both sides
are sprayed simultaneously. The picture shows the upper spray gun.

Depending on the storage area atmosphere, the coated tubes can be
stored for days up to several months. The storage should be clean and
with no contamination of the coating.
This coating method consumes more paste than needed for the tubes
(over-spraying). Work is going on to minimize this amount. You
should avoid applying too much paste, as the excess amount can drip
in the furnace and deteriorate the muffle below, if there is one.

4.1.2 Development of tube coating methods
Recent development work has resulted in optional concepts where
coating of tubes can be integrated with the tube welding line.

38

39

Consumption of brazing paste could in most cases, depending of the
fin density, be reduced by applying the paste on the tips of the fins
rather than on the tubes. Some solvent-based pastes are suitable for
fin-tip application. When using solvent-based pastes, the tips of the
fins are coated on one side at a time with drying between.
The coating thickness is measured by weighing; the recommended
amount of paste on each tip is 0.3 mg/mm to 0.5 mg/mm of fin
width. Again, the better the fit between fin and tube the smaller the
amount of paste application on the tips. Table 8 shows some
examples of amount of paste for some fin widths and density. In the
table fpi is the number of fin tips per inch.
The fin tips are coated by contact with paste coated rolls. Depending
of the storage atmosphere, the coated fins can be stored for days up
to several months. For all types of storages, it should be clean and
with no contamination of the coating.

Table 8. Example of the amount of paste on the fin tips. Fpi = fins
per inch.
Paste, g/m fin Fin width
mm
Paste
g/tip
15 fpi 20 fpi 25 fpi
16 0.008 4.7 6.3 7.9
20 0.01 5.9 7.9 9.8
40 0.02 11.8 15.7 19.7
60 0.03 17.7 23.6 29.5
80 0.04 23.6 31.5 39.4
100 0.05 29.5 39.4 49.2

40
4.3 Tube-to-header joints

A dedicated paste (sometimes called slurry) is recommended for
tube-to-header joints. This paste has a lower viscosity than the pastes
for tube coating and can be applied by pouring or spraying. Normally
the paste is applied on the airside of the header. The volume of the
paste is around double the volume of the filler metal in the joints
after brazing. The visible amount of paste should therefore be more
than what the joints are expected to be after brazing. The amount of
paste required is typically 0.5 g (dry weight) per each tube end for 16
mm wide tubes and 1.8 g per tube end for 60 x 6 mm tubes. These
quantities are just guidelines, as the amount of paste is influenced by
the geometry of the joint. Formula 2 shows guideline for calculating
the amount of paste for other tube dimensions.

E = (H + W)/36 [2]

Where
E is the amount of dried paste on the tube end (g)
H is the height of the tube (mm)
W is the width of the tube (mm)

And for a total amount on a header (g)

N x (H + W)/36

where N is the quantity of tubes.
For multi-row cores it is important that the paste is evenly distributed
at all joints. Do not apply paste more than necessary, as the excess
quantity can drip in the furnace and deteriorate muffle below, if there

is one. Also the excess amount can form solidified droplets on the
header. Those droplets are troublesome to remove by grinding .
A small amount wetting agent or flux is normally included in this
kind of paste to make the brazing process more forgiving when
slightly oxidized components are used. A flux free paste exists, as
well, and can be successfully used when parts are clean and the gap
widths are according to specification.
The paste application methods are well suited for automation. Figure
15 illustrates the principle of paste application to headers. For small
production the paste can be applied manually as shown in figure 10.
When coating and drying manually, do not overheat the paste when
drying with warm air. The brazing properties will be destroyed if the
paste is heated above 130 C. On the latest header paste machines the
drying is done with IR-lamps instead of warm air.
It is recommended to braze the parts within 1-2 days after applying
header paste, depending on the storage atmosphere.

Figure 15. Method of applying paste on headers. In an automatic
line, the paste can be applied on both sides simultaneously.
41

Figure 16. Manual application of header paste.
Important
The brazing properties will be destroyed if the paste is heated above
130 C during drying.
_________________________________________________

42

5. Fabrication and assembly of
components

5.1 Tubes
5.2 Fins
5.3 Headers
5.4 Surface conditions.

43

5. Fabrication and assembly of components

All furnace brazing operations, among them CuproBraze, require
narrow tolerances. Generally, closer tolerances and well-defined joint
gaps result in better and stronger joints, see figure 17.

Figure 17. Diagram showing filling length in gap with different
clearance.

Another factor to take into account is that the brazing alloy is in
powder form and it builds up a thicker layer than a solid metal. The
geometry of the tubes and fins and the tube pitch in the header should
be adjusted accordingly.

44

5.1 Tubes

The tubes are usually made by HF (high frequency) welding. These
tubes are uniformly made from strip because thin gauges are required
for lightness.
Tube fabrication requires that the edges of the strip are reliably
bonded together.
Tubes for use in the CuproBraze process should be specified with a
crown that is higher compared to the crowns of tubes for use in a
soldering process. The crown (see Figure 18) should be 0.4 mm to
0.8 mm for tube widths 12 mm to 25 mm. A higher crown results in a
more consistent bond between tube and fin, see chapter 11.

Figure 18. Definition of the crown of the tube. Crown is W
2
W
1

HF- welded tubes are most commonly used today for CuproBraze
heat exchangers because their contoured shape is uninterrupted
around the circumference of the tube. As a result, a consistent gap
can be achieved between the tube and the header. HF-welded tubes
are commercially available.
45

46
When welding tubes of brass strip for CuproBraze, note the
differences in the material performance as described in part 2.2 (Fig.
5). as this can effect the settings of the welding parameters.
When bare CuproBraze tubes are produced, careful rinsing and
drying are needed to avoid discoloration.
_____________________________________________________
Important
Tubes for use in the CuproBraze process should be specified with a
crown that is higher compared to the crowns of tubes for use in a
soldering process.
Note the differences between conventional and CuproBraze tube
materials when HF-welding
________________________________________________

5.2 Fins

Consistency in the fin amplitude is also important. Inconsistency in
the fin height can result in gaps that are too large between fin tips
and tubes with the consequence of low percentage of correctly
brazed tube-to-fin bonds. Sometimes too big amounts of brazing
paste on the tubes are used.

47

5.3 Headers

The holes in the header can be designed and manufactured in
different ways, see one example in figure 19. For the CuproBraze
process, pierced holes are recommended using a two-stage operation,
which creates a continuous collar of contact surface area between the
header and the subsequently inserted tube. This shape draws braze
alloy from the surface of the header into the joint by capillary action.
The optimum capillary action is reached at 0.05 mm joint clearance
which means that the optimal size for the gap between header and
tube is 0.05 mm and this gap should not exceed 0.1 mm. No fraying,
tears or breaking is allowed in the joint section.
Stiffening ribs on the header are also beneficial (See figure 20).
Besides functioning as reinforcement, ribs lower the slurry
consumption. Paste flowing into the wells around the tubes is not
wasted on areas between tubes. When header gauges are smaller than
0.8 mm (0.03 in), extra care is recommended with tabbed header
design from the strength point.
The type of oil used in the stamping process normally leaves
unwanted residues after brazing; this negatively influences the
brazing of the tube-header joints.
_____________________________________________________
Important
If the stamping oil gives this problem, which can be seen as dark
surface of the header after brazing, the headers have to be degreased
before assembling or the stamping oil has to be replaced.
________________________________________________

Figure19. Pierced holes (left and middle) in header are
recommended. No fraying, tears or breaking is allowed in the joint
section. Lanced holes (right) are used for soldering but are not
recommended for brazing.

Figure 20. Stiffening ribs on header have not only positive effect on
the strength but also help minimizing the dripping of the paste in the
furnace and forming of solidified droplets on the header.

_______________________________________________________
Important
Optimal size for the gap between header and tube is 0.05 mm; this
gap should not exceed 0.1 mm.
_________________________________________________

48

49

5.4 Surface conditions

At the brazing temperature, the surfaces of the components to be
joined, as well as the brazing powder must be free from any non-
metallic films, such as organic residues and metal oxides. In the
brazing process, there is nothing, which can remove any dirt, heavy
oils and oxides. To be able to wet and alloy with the components,
they have to be clean before brazing. All storing of the components
must be done in such a way that no contamination of any dust,
chemicals and oxides take place, especially the paste coated parts
that are very sensitive.

Most types of oils on copper and brass surfaces will form black or
even invisible organic residues after heating in nitrogen atmosphere.
The residues will be very thin films, which sometimes can be
difficult to remove.
Oils with low boiling point do not normally form this kind of organic
residues.

_______________________________________________________
Important
The oil on the surfaces after fin and tube production, is normally not
harmful.
_________________________________________________


As previously mentioned, the brazing powder builds up a thicker
layer than a solid metal of the same weight. This extra thickness must
be taken into account when specifying tube pitch in headers and
brazing-fixture devices.
The tube pitch (see figure 21) in the headers is a function of the tube
width and fin amplitude with an allowance for a brazing paste layer.
The allowance for brazing paste in turn depends on the tube
dimension, the core width and the fin design. The brazing paste
allowance has to be determined with actual components. As a
guideline, increasing the pitch by 0.10 mm often works well,
resulting in a complete brazed joint between fin and tube. But for
optimal brazing result, it is recommended to check the brazing result
between the tubes and the fins for the first sample before further
work. Figure 22 illustrates the shape changes of the tubes during
compression of the core. See also figures 18 and 23.
The virgin tube has a convex belly, when the tube is compressed it
starts flattering. If it is compressed too much, the tube walls will be
bent inwards in the centre and become concave.

Figure 21. Definition of the tube pitch.

50

51

Figure 22. The figure illustrates what happens to the tubes during
compression of the core. The virgin tube (A) is convex, when the core
is compressed to right dimension the tube sides are flat (B). If the
core is compressed too much, the tube is formed to dog-bone (C).

In the CuproBraze process the parts go through a temperature cycle
from room temperature up to 650 C, which means that the
differences in the thermal expansion will influence the fixture design.
Table 9 shows the thermal expansion coefficient and the expansion
for 1 meter of the material from 25 C to 650 C.

Table 9. The heat expansion and the increase in length (l ) from 25
C to 650 C for 1 m long object.

Material
Heat expansion
coefficient
m/mC
l
for
25 650C
in mm
Copper fin SM 0502 17 10.6
Tube brass SM 2385 19 11.9
Header brass SM 2464 20 12.5
Steel 11 6.7
Stainless steel 15 9.4

The assembly and brazing-fixture system should allow for the
convex shape of the core before brazing, due to build-up of brazing
paste and the heat expansion of the fixture. For a 500 mm x 500 mm
core, a typical dimension measured in the middle of the core is 502.5
mm to 503 mm, see figure 23.

Figure 23. Radiator core shape before and after brazing. Before
brazing the example core is belly, width in the middle 502.5-503
mm. In brazing the core width shrinks to 500 mm.

Another requirement of the brazing fixture is the demand for a
reduced mass that allows the fixture to follow the temperature of the
radiator core as closely as possible. This arrangement prevents
differences in dimensions due to temperature variations that could
lead to permanent deformation of fins or tubes. For the same reason,
the fixture material should have a thermal expansion coefficient as
close as possible to that of brass, favoring stainless steel instead of
carbon steel.
52

A slight flexibility in the fixture (to allow it to follow the core when
the brazing paste melts) is also recommended, especially for larger
cores.
Due to the differences of the heat expansion for header brass and the
stainless steel in the fixtures, especially careful work has to be done
when designing the fixtures in the corner area of the cores. Figure 24
shows schematically what happens in this area during brazing.

Figure 24. Principles for the influence of the heat expansion in the
corner of the core. At room temperatures (left) and at brazing
temperatures (right).

In figure 24, l
h
is the distance between the outer tubes and l
w
is the
length of the steel fixture. At brazing temperature, the steel fixture is
shorter than the distance between the outer tubes. If the steel part is
too short from the beginning or the fixture is placed too close to the
header, the outer tubes will be crushed and leakage in the tube-
header in the corner area will appear.
It is preferable to design with side supports that are mechanically
attached to the header prior to brazing. These supports provide a
well-defined gap during the entire brazing cycle for the outermost
fins that are close to the header. In this manner, brazing voids or
deformation of the fin or tube in the corner region can be avoided.
53

54

6.1 Atmosphere

55

Because the amount of flux in the CuproBraze process should be
zero or absolutely minimal, and the parts should be oxide free after
brazing, an inert atmosphere is needed to prevent oxidation of the
parent and filler materials. As the brazing temperature is much lower
than the melting points for the copper and brasses, the temperature
differences in the parts during the brazing process are not critical. As
the CuproBraze process works with parts from around 100 g up to
more than 100 kg it is not possible to advise exact settings of the
furnaces.

6.1 Atmosphere

The primary function of the brazing atmosphere is to prevent
oxidation. Furnaces for the CuproBraze process use high-purity
nitrogen to displace oxygen (air) from inside the furnace. The
atmosphere of the furnace must have an oxygen content of less than
20 ppm and dew point of less than - 40
o
C always when the
temperature is elevated above ambient. The brazing powder becomes
very sensitive for oxidation when the binder starts to evaporate. If
moisture and oxygen levels are higher than critical levels, the powder
and the base material have a risk of oxidation at temperatures
exceeding about 200 C resulting in very poor joints. Thus the
starting point of the brazing cycle is as sensitive for oxygen-content
as the rest of the cycle.
Mixing the brazing atmosphere with hydrogen (H
2
) is occasionally
suggested. Hydrogen can sometimes react with the organic binder
forming products which can have a negative influence on the brazing

56
result. Before using hydrogen or hydrogen mixed atmosphere, the
paste manufacturer should be consulted.
_____________________________________________________
Important
The oxygen content should be controlled from the time when the
heating starts and no heat should be applied if the required
atmospheric conditions are not met.
_________________________________________________


The difference in the melting points for the filler metal and the
copper and brass materials is more than 300 C, which means that
there is no risk to destroy the parts by melting. The temperature
above the melting point for the filler metal (600 C) should be as
short as possible but still gain a satisfactory brazing result. It means
that the furnace must be able to heat up the load in the brazing zone
with a steep ramp. A common value is more than 30 C per minute.
The furnace must be able to operate up to 700 C. Figure 24 shows a
principal temperature-time curve for the CuproBraze process in a
continuous furnace.

Figure 25. Example of temperature-time curve for the CuproBraze
process. The curve is individual for each type of furnace.

In the section A, the sample is slowly heated up and the binder
evaporates and/or is decomposed. When the binder disappears, it
leaves the powder particles in the brazing paste without any
protection from oxidation if the oxygen content is too high. The
oxygen content should therefore be controlled from the time the
heating starts. No heat should be applied if the required atmospheric
conditions are not met. The brazing result will be poor if the brazing
powder is oxidized before it starts to melt. Note that big heat
exchangers, as well as one-shot heat exchangers, can include small
partly closed pockets, which can influence the necessary time to
reach acceptable oxygen content in those pockets. Good convection
in the furnace is therefore recommended.
By the rather slow heating rate in this zone, the temperature
differences in the samples are minimized, and the distortion of the
sample due to heat expansion can also be minimized.
In section B the whole core will be preheated to just under the
melting temperature of the brazing metal. To make the temperature-
differences in the core at brazing as small as possible, the section B
should be designed so that the temperature in the whole heat
exchanger is as equal as possible when the brazing zone is entered. In
some batch furnaces, there is no pre-heating and in that case furnace
57

58
settings that minimize the temperature differences in the heat
exchanger have to be used.
Section C is the brazing zone. When the temperature exceeds 600 C,
the brazing filler metal (powder or foil) starts to melt. When it melts,
metallurgical reactions (diffusion) start and the extent of the filler-
substrate interaction is the most important. The fin material starts to
be alloyed with tin coming from the filler material and forming a
copper-tin alloy close to the joint. It does not influence the
performance except for exceptional long brazing times, where some
loss of thermal performance (up to 10 %) of the heat exchanger can
occur.
The governing factor for the brazing cycle in most cases is the
brazing of the tube-header joints. In chapter 5 figure 11 it is shown
that the brazing temperature has a big impact on the ability of the
brazing alloy to satisfactorily fill gaps. In practice it has been found
that to satisfactorily wet the surfaces and fill the joints, you should
ensure that the temperature in the joints exceeds 650 C.
As the alloying reaction starts when the molten filler metal wets the
surfaces, the time above 600 C should be kept as short as possible
but still long enough for the tube-to-header joints to reach minimum
650 C. For small radiators, 3 to 4 minutes brazing time is typical. For
bigger heat exchangers the time can be longer.
At too low brazing temperature or too short brazing time the
conductivity of the fin alloy does not reach the target level. At too
high brazing temperature or too long brazing time, the fin gets
alloyed by the brazing material with the consequence of reduction in
the thermal conductivity of the fin. Therefore, it is important to
optimize the brazing temperature and time and control that they are
kept within specified limits.

59
The effect of the brazing cycle on the tube-to-fin joints cannot be
seen by naked eye. During optimization of the brazing cycle,
overshooting of the brazing temperature can sometimes happen, but
it will not lead to any noticeable visual effect on the brazed heat
exchanger as the melting point for copper and brass is far higher than
the brazing temperature.
To minimize the risk for distortion of the joints during cooling
section D, it is recommended to have a low cooling rate down to
around 550 C, typical value 1 C/s.
To prevent discoloration of the brazed parts, they should not leave
the inert atmosphere until the part temperature is below 150 C. In
places where the ambient humidity is high the exit temperature
should be even lower to prevent discoloration. Note: The possible
discoloration is only a cosmetic effect and it will not deteriorate the
brazed joint.
During optimization of the brazing cycle, it is highly recommended
that measurement and recording of the temperature with
thermocouples, mounted in the core, is used. To have full control on
the brazing process, it is recommended to also have this tracker
equipment available to check the process every now and then during
ordinary production. If it is not possible to use the thermocouples
together with equipment outside the furnace, it is recommended to
use them with a tracker following the sample through the furnace.
The brazed part should be cooled down as uniformly as possible, at
least in the beginning of the cooling, to prevent deformation. The
temperature drop rate should be equal in the whole core. One way to
achieve this is to slow down the cooling until 550 C. At that
temperature, the filler metal in the joints is no longer molten.
To satisfactorily wet the surfaces and fill the joints, ensure that the
temperature in them exceeds 650 C.

60


7.1 Batch furnace



7.4 Heating source

61

Factors to consider when selecting a suitable furnace are production
volume, part size, available floor space, capital expense, and
operating cost. Based on these specifications, the CuproBraze heat
exchangers can be processed in batch, semi-continuous or continuous
furnaces.
Selecting a suitable furnace requires knowledge of the temperature,
time and atmospheric conditions of the process. All of the furnaces
have heating and cooling sections. Batch furnaces and semi-
continuous furnaces are suitable for any part size but limited with
respect to production volume. Continuous furnaces are suitable for
high volume production.

7.1 Batch furnace

A batch furnace uses the same door to load and unload the part.
These furnaces can only produce one batch at a time. A load is
purged with nitrogen then moved into the brazing chamber; after
brazing, the load is moved back into the purge chamber where it is
cooled.


In a semi-continuous furnace parts are indexed from the loading area
to the purge chamber, where the part is purged with nitrogen and
then moved into the next chamber. The furnace simultaneously
moves the purged part into the brazing chamber and a new part into

62
the purge chamber. This type of furnace is suitable for large parts
and/or intermediate volume production. The most popular type of
furnace has 3 chambers in row. The mid chamber is for brazing and
it can be entered from the two other chambers which are both for
purging and cooling.


A continuous furnace uses a conveyor-belt to continuously move
parts through the furnace where they are continuously purged with
nitrogen, brazed and then cooled. This type of furnace is for high-
volume production. A continuous furnace is not recommended for
parts longer than 1000 mm because when the front of the part enters
the heating zone, it conducts heat to the rear of the part. As a result,
the trailing section of the part is held at temperature for a much
longer time than the leading edge of the part.

7.4 Heating source

It is possible to heat all three types of furnaces with electricity,
natural gas, or propane/butane. In many countries, natural gas and
propane are a cheaper source of energy than electricity, but they
require more maintenance and have a higher initial cost. Gas burners
also require a gas-tight barrier between the combustion products and
the brazing atmosphere. Such a barrier can be radiant tubes or a
muffle.

63
8. Process emissions

Process emissions are generated when applying paste on tubes and
headers and when the binder is volatilized in the furnace. These
emissions must be properly managed to prevent contamination of the
atmosphere inside the plant, the furnace and the environment
surrounding the plant.
The constant flow of nitrogen normally expels the vapour from the
brazing atmosphere in the furnace. As there is no oxygen available to
burn the gas products in the furnace, the gases must either be burned
outside the furnace or diluted with ambient atmosphere. The local
regulations require in most cases, some kind of afterburner.
The laws vary from country to country and state to state, so one must
check with the local authorities in advance. The generated emissions
are influenced by the binder systems and can be totally different
between paste manufacturers. Further information regarding the
emissions, and further handling of them, are obtainable from paste
and furnace manufacturers.

_______________________________________________________
Important
Most of the binders in the pastes form emissions. Consult the local
environmental authorities and the paste manufacturer to check if any
kind of afterburner must be used or is recommended.
_________________________________________________

64

9. Corrosion Resistance




9.4 Coatings

65
9. Corrosion Resistance


Normally, no cleaning is needed after the brazing operation.


The corrosion resistance of CuproBraze radiators is generally better
than that of soldered radiators and very competitive with that of
aluminum.
When different metallic materials are used in the same cooling
system, questions sometimes are raised about possible micro-
galvanic corrosion risk, considering that the noble metal (copper)
deposits on the unnoble metal (aluminum) surfaces. Inhibitor
systems in the coolant are designed to prevent all kinds of corrosion
in the cooling systems, including microgalvanic corrosion and, for
this reason, the maintenance of the coolant is important. In general,
however, copper alloys are less sensitive to a bad coolant than
aluminum.
Corrosion test results in coolants for CuproBraze materials
(including tube brass SM 2385 and header brass SM 2464) are
similar to test results for copper-based materials used in soft-soldered
radiators. In a study on a mixed-metal cooling system, there was no
indication of micro-galvanic corrosion on aluminum caused by
copper. Therefore, the coolants that fulfill the standard requirements
with copper materials are considered compatible with materials used

66
in CuproBraze radiators, and vice versa. CuproBraze heat
exchangers are compatible with mixed-metal cooling systems.


The risks of external corrosion caused by galvanic attacks is
minimized by the fact that the materials in CuproBraze radiators,
including the copper-fin alloy, brass-tube alloy and the brazing alloy,
have about equal mutual nobility. The brass-tube alloy contains 85 %
copper, which means that the alloy is less sensitive to stress
corrosion cracking and dezincification than conventional brass
alloys.
The brazing alloy OKC600 (CuNiSnP-type) also provides an extra
protective and mechanically strengthening coating for tubes. It is also
increasing resistance to sand erosion. Corrosion test results have
been published. The references were soldered copper-brass radiators
and brazed aluminum radiators. According to the results from four
different kinds of accelerated corrosion tests, CuproBraze radiators
were generally more corrosion resistant than soldered copper-brass
radiators and very competitive with aluminum radiators. Generally,
aluminum radiators were more prone to localized corrosion forms,
whereas the corrosion form on CuproBraze was usually even and
thus predictable.

67
9.4 Coatings

CuproBraze radiators are mechanically strong and facilitate thickness
reductions High-performance coatings further improve corrosion
resistance and make thickness reductions possible without risks from
corrosion.
There are different ways to increase external corrosion resistance
when reducing thickness. The easiest way is to leave the commonly
used cosmetic coating off totally. An uncoated radiator has a lifetime
that is about 30 percent longer than the lifetime of a cosmetically
spray-coated radiator.
Electrophoretic coating is the best technical solution to increase
corrosion resistance. It increases the lifetime by 2.5 to 3 times
compared to an uncoated radiator. A new option is powder coating
with a multi-nozzle spray gun, which gives good results with respect
to corrosion resistance and thermal performance and has a lower cost
compared to an electrophoretic coating.
High-performance coatings cover the entire external radiator surface
(not just 10 % of it, as is the case for most conventional cosmetic-
spray coatings). They clearly prolong the lifetime of the radiators.
These technologies are commercially available.

68

10.1 One-shot brazing

10.2 Brazing of parts with internal turbulators (CAC).


69


10.1 One-shot brazing

One-shot brazing is when all or most of the joints in the heat
exchangers are brazed simultaneously in one brazing cycle and there
are no metallurgical differences between one-shot and other brazed
joints. If the brazing parameter criteria for all joints are fulfilled, the
joints will be satisfactorily brazed. There are some points to be noted.
If the one-shot brazed heat exchanger includes inner fins or other
kind of internal joints, it must be ensured that the atmosphere
around all joints is in line with the recommendation stated in chapter
6.1. In most cases, purging inside the heat exchanger with nitrogen is
necessary. To ensure good brazing results in all joints, the joint
geometry, as well as fixturing and paste application, should be
designed for furnace brazing. During the brazing process, some
movements between parts in the joints can take place due to stress
relieving in stamped parts and also due to differences in thermal
expansion between the parts. When designing for one shot brazing
this should be taken into account. If possible, self-fixturing of the
parts should be used.
The design for soldered tank-header joints, in most cases, has gaps
that are too wide for satisfactory brazed joints. The design for brazed
joints should have a gap of 50 m, optimally, and in maximum 100
m.
Figure 26 shows a typical geometry for soldering of header-tank. In
figure 27 some improved header-tank designs are shown.

70

header
tank

Figure 26. Typical joint for soldered header-tank. Gaps are too large

Figure 27. Alternative joint geometries for header-tank.

Many of the joints in one-shot brazing are placed upside down or
horizontally, it is therefore important to use a brazing paste suitable
for this kind of joints.
The brazing paste should (if possible) be applied just outside the
joints. During brazing the molten filler metal will be drawn into the
joint by capillary force.
One-shot brazing is already in commercial production by a few
companies. One of them has brought it already to volume production
scale.

10.2 Brazing of parts with internal turbulators (CAC)

Brazing foil is the primary recommendation as filler metal for
internal turbulators inside tubes, especially for charge air coolers
(CAC). The foil can be inserted together with the turbulators from
the end of the tube, see figure 28.

Figure 28. Brazing foil used for internal turbulator brazing.

When turbulators similar to ordinary corrugated fins for heat
exchangers are used, they should be designed to take up some elastic
movements during the brazing cycle. If very stiff turbulators are used
they can form a split in the sample after brazing.


Brazing any steel parts is not recommended, due to formations of
brittle Fe-P-film between the filler and the base metal.
71

72
11. Quality control



11.3 Visual inspection of the tube-fin joints after cutting of
the fin.

11.4 Cross sections of the joints.

11. Quality control


An example of quality control scheme before brazing is shown in
figure 29.

Tube
material
Header plate
material
Fin material
Check
material,
dimensions
Check
material,
dimensions
Check
material,
dimensions
Tube production
Header plate
production
Fin production
Check
dimensions
Check
dimensions
Check
dimensions,
surface
Paste application
and drying
Check
paste amount
Core assembly
Header paste
application
Check
paste amount
Brazing

Figure 29. Quality control scheme prior to brazing.
73

74

The incoming materials must be stored so that they do not oxidize
during storing. The brazing results can be checked by
- Visual inspection in general.
- Visual inspection of the tube-fin joints after cutting of the
fin.
- Cross-sections of the joints.


The products should be clean with no heavy oxidation (if flux
containing paste is used on the headers, they will leave some black
parts on the joints). The side supports should be straight with no
splits in the cores.

11.3 Visual inspection of the tube-fin joints after cutting of
the fin

As this inspection is destructive it should be used on only for a
minimum number of components. The fins are cut off and the
completeness of brazed joints is investigated. It is recommended to
check the tube-fin joints for the first samples when something in the
production has been changed. The check should be repeated until the
right quality has been reached. Figure 30 shows high quality brazed
tube-fin joints.

Figure 30. Examples of high quality brazed joints.

11.4 Cross sections of the joints

Investigation of cross sections of the joints is a method to look at the
joints in a scientific way. Cross sections of all kind of joints as well
as welded tube joints can be studied. Except for examination of
welded tube this kind of investigation is not needed for ordinary
production.
Figures 31-33 show some typical examples of cross sections of good
brazed joints.

75

Figure 31. Example of tube-fin joint.

Figure 32. Example of good tube-header joint.

76

Figure 33. Examples of cross-sections of tube welds.

77

78
12. Reparability

12.1 Soldering
12.2 Re-brazing

79

12. Reparability

Reparability is one of the major advantages of CuproBraze heat
exchangers.

12.1 Soldering

CuproBraze heat exchangers can be repaired both at the
manufacturing plant and in the field with lead-free solders. In the
CuproBraze process, copper-tin, copper-phosphorous and nickel-
phosphorous compounds are formed during brazing. Due to
decreased wetting of these compounds compared with brass and
copper, efficient fluxes have to be used. Many of the fluxes used in
conjunction of brazing stainless steel can satisfactorily be used in
repairing CuproBraze components. Some of these fluxes leave
corrosive residues, so careful rinsing after repairing is essential.

12.2 Re-brazing

Another repair method at the manufacturing plant is to apply
additional brazing paste at the failure site. In this case the component
should be dried and re-brazed using the same brazing cycle as is
normally used in manufacturing. During re-brazing the fins will
become slightly softer. Due to increased alloying of the fins, the
thermal performance of the heat exchanger may somewhat decrease.
The heat exchanger should be re-brazed with the opposite side up
compared to the original brazing, in order to keep tube-to-header

80
joint sealed. It is advisable to check for any tube-to-header leaks and
repair if necessary.


Repairing with conventional low melting AgCuZnSn filler metals
together with a suitable flux is also possible. Rinsing
recommendations from the flux manufacturer should be followed to
remove possible flux residues.

81
13. Troubleshooting

82

13. Troubleshooting

Crushed fins after assembling.
Problem: The fin height does not match the coated tubes.
Countermeasure: Adjust header pitch or fin height.

The headers are black after brazing.
Problem: The headers have oil residues after brazing.
Countermeasure: Degrease them before assembling.

Bad brazing of tube-to-fin and soot-like residues on the tubes.
Problem: The brazing powder has been oxidized during heating.
Countermeasure: Check the oxygen-content in the first part of the
brazing cycle. Check the drying of the paste.

Insufficient brazed fin-tube joints along the center part of the tubes.
Problem: Example of insufficient brazing between tube and fins is
shown in figure 34. The compression of the core was too high during
the brazing operation or the tubes had too low crown.

Figure 34. Examples of bad brazing between tubes and fins.

Countermeasure: Increase the pitch in the headers (by 0.05 0.1
mm). Check the fixturing. Check that the crown of the tubes is
correct.

No brazing at the tube edges.
Countermeasure: Decrease the pitch in the headers
(by 0.05 0.1 mm) or increase fin height.

Unbrazed joints - not uniformly distributed on the tubes.
Possible causes: Too low amount of paste on the tubes. Fin height
variation. Surface quality of tubes.

Bad brazing of tube-to-fin with rough and dark surfaces.
Countermeasure: Check the brazing parameters and the fixturing of
parts. All areas of the core have to reach the brazing temperature.

83

84

Tube-header leakage - randomly distributed.
Countermeasure: Check the brazing time and/or temperature. Could
be too low. Check the amount of paste on the tube-header joints.
Check the surface conditions of the headers and on the tube ends.

Tube-header leakage in the corner area of the core.
Countermeasure: Check the fixturing close to the corner. Could be
too tight.

The whole heat exchanger is dark.
Countermeasure: Check the oxygen content in the cooling part of the
furnace. Check the exit temperature of the part.

85

14. Getting started

14.1 Contacts


86
14. Getting started

To produce brazed prototypes in copper and brass and develop the
CuproBraze process, Luvata has a Brazing Center in Sweden. In the
Brazing Center, it is also possible to show some steps of the process
in pilot scale. An overview picture of the Brazing Center is shown on
the cover of this book.
The interest in CuproBraze technology has accelerated in recent
years. As a result, a global network of suppliers and users of the
process have formed CuproBraze Alliance (www.cuprobraze.com)
and stand ready to assist manufacturers in establishing volume
production facilities based on the CuproBraze process.
In addition, the Luvata Brazing Center in Sweden is ready to
demonstrate the brazing processes. The Center can also help to
evaluate the technology through prototype building, and training
programs, at cost coverage basis.
A new start-up option became available in 2007, low cost
CuproBraze line concept, developed by a group of companies
within CuproBraze Alliance.

14.1 Contacts

Luvata Sweden AB, with its CuproBraze Team and Brazing Centre,
supports its customers to get started with CuproBraze. Download this
Handbook as pdf-file.

Website: www.luvata.com Contact: [email protected]

87


www.cuprobraze.com,
Website of the CuproBraze Alliance. General and specific
information. Download this Handbook as pdf-file. Links to suppliers
and other members.
www.cuprobraze.com/lit_er.asp
ICAs CuproBraze Executive Reports.
The ICA CuproBraze Executive Report provides updates on all
aspects of CuproBraze technology, including news about suppliers,
materials, equipment, production lines, manufacturers, product
design, industry trends and marketing strategies. It is published
approximately ten times per year and is available as printed version
free-of-charge from the International Copper Association, in addition
to the pdf-format on the website.

www.copper.org and www.copperinfo.com
Websites of the International Copper Association (ICA) and Copper
Development Association (CDA).
www.luvata.com, www.luvata.com/Automotive-Newsletter
Luvata Automotive Newsletters.

88


89


There is continuous development going on improve productivity,
quality and to lower cost.
A low cost start-up line concept has been created by some member
companies within CuproBraze Alliance.
As regards the process equipment, there is development to integrate
the tube welding line and paste application on tubes. Similar
development is with integrating tube welding with thermal coating of
tubes by brazing alloy.
Multiport copper tubes have been developed and they are on the way
from pilot scale to commercial production. This kind of tubes can be
used in condensers, internal oil coolers, heat pipes for electronics
cooling etc.
An anticorrosion coating has been developed for turbulators inside
CAC tubes. This way exhaust gas resistant construction can be
achieved. This concept can be suitable also for other type of
corrosive conditions.
More information on the developments can be found on
www.cuprobraze.com .

90


91

Materials
For the CuproBraze process special copper and brass materials
should be used.
- SM 0502 for fins
- SM 2385 for tubes
- SM 2464 for headers, side supports, tanks and other parts.

Brazing materials
Brazing paste or brazing foil has to be used. The brazing alloys are
shown in table.

Brazing alloy Copper
Cu
%
Nickel
Ni
%
Tin
Sn
%
Phosphorus
P
%
Melting range

C
OKC 600 Balance 4.2 15.6 5.3 600 - 610
VZ 2255 Balance 7.0 9.3 6.5 600 - 630

OKC 600 is used for powder and VZ 2255 mainly for foil.

Brazing pastes
To make it possible to apply the brazing powder for brazing of the
cores, it is mixed with a binder and solvent to a suitable brazing
paste. The binder is mostly specific for each paste manufacturer;

92
hence pastes from different manufacturers must not be mixed
together. Application can then be done by means of conventional
commercial application methods.
All pastes are premixed and are ready to use after stirring. The
stirring recommendations from the paste manufacturer should be
followed in order to secure good paste applicability. There are pastes
with different viscosities to be used at different kinds of joints.
The solvent of the paste is evaporated during drying. Remaining
powder and binder will form a hard coating after drying.
The pastes normally have a long shelf life. For detailed information
regarding the paste types and properties, contact the paste
manufacturer.

_______________________________________________________
Important
Do not make a mixture of pastes from different manufacturers as the
binders may not be compatible with each other.
__________________________________________________

Brazing paste application at tube-fin joints
For tube-to-fin joints, brazing paste can be applied on the tubes.
The most commonly used method for coating the tubes is spraying
with commercial spray guns. It can be done by manually as well as
by automatic spraying.

93
Coatings should be evenly applied with a coating weight of 150-250
g/m
2
after drying. The better the tolerances of the tubes and fins are,
the thinner the layer can be. It is recommended to start with the
thickest (heaviest) coating.
It is recommended not to coat the tube ends. If the tube ends are
coated it can sometimes have a negative influence on the joint quality
of the tube-header joints.
The brazing properties of the pastes can be destroyed if the
temperature in the coating is above 130 C during drying.
Instructions from paste suppliers must be followed.
_______________________________________________________
Important
__________________________________________________
Brazing paste application at tube-header joints
A dedicated paste (sometimes called slurry) is recommended for
tube-to-header joints. This paste has a lower viscosity than the pastes
for tube coating and can be applied by pouring or spraying. Normally
the paste is applied on the airside of the header. The amount of paste
required typically is 0.5 g per tube end for 16 mm wide tubes and 1.8
g per tube ends for 60 x 6 mm tubes. These quantities are just
guidelines, as the amount of paste is influenced by the geometry of
the joints and headers.

94
_______________________________________________________
Important
__________________________________________________

Brazing of parts with internal turbulators (CAC)
Brazing foil is recommended to be used as filler metal for internal
turbulators, especially for charge air coolers. The foil can be inserted
together with the turbulators.

Brazing fixtures and assemblies
The brazing powder in the paste builds up a thicker layer than a solid
metal of the same weight. This extra thickness must be taken into
account when specifying tube pitch on headers and brazing-fixturing.
The tube pitch in the headers is a function of the tube width and fin
amplitude with an allowance for a brazing paste layer. As a
guideline, increasing the pitch with 0.10 mm per tube often works
well, resulting in a completely brazed joint. But for optimal brazing
result, it is recommended to check the brazing result between the
tubes and the fins for the first sample before further work.
In the CuproBraze process the parts go through a temperature-cycle
from room temperature up to 650 C, which means that the
differences in the thermal expansion will influence the fixture design.

95
Brazing operation
Furnaces for the CuproBraze process use high-purity nitrogen. The
atmosphere of the furnace must have an oxygen content of less than
20 ppm from the time when heating starts. The brazing powder is
very sensitive when the binder starts to evaporate. Therefore the
starting point of the brazing cycle is as sensitive for oxygen-content
as the rest of the brazing cycle.
___________________________________________________
Important
The oxygen content should be controlled from the time when the
heating starts and no heat should be applied if the required
atmospheric conditions are not met.
___________________________________________________

The difference in the melting points for the filler metal and the
copper and brass materials is more than 300 C, thus there is no risk
of destroying the parts by melting. The time above the melting point
for the filler metal (600 C) should be as short as possible but still
gain a satisfactory brazing result.
To satisfactorily wet the surfaces and fill the joints, ensure that the
temperature in them reaches 650C or for some new types of header
pastes even 660 C.
To minimize the risk for distortion of the joints during cooling (part
D), it is recommended to have a low cooling rate until around 550
C, typical value 1 C/s.
To prevent discoloration of the brazed parts, they should not leave
the inert atmosphere until the component temperature is below

96
150C. In places where the ambient humidity is high the exit
temperature should be even lower to prevent discoloration. Note:
This discoloration is only a cosmetic effect and it will not deteriorate
the brazed joint.
During optimization of the brazing cycle, it is recommended to
measure the temperature with thermocouples mounted on the core.
The effect of the brazing cycle on the tube-to-fin joints cannot be
seen by the naked eye. During optimization of the brazing cycle,
overshooting of the brazing temperature can sometimes happen, but
it will not lead to any noticeable visible effect on the brazed part.

97
POINTS FOR SUCCESS

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.

98
References

1. Gustafsson B. and Scheel J ., CuproBraze Mobile Heat Exchanger
Technology, SAE Technical Paper Series 2000-01-3456.
2. Falken A. and Ainali M., OCP-materials, SAE 01 HX-18.
3. Tapper L. and Ainali M., Interactions between the materials in the
tube-fin joints in brazed copper-brass heat exchangers, SAE 2001-
01-1726.
4. Korpinen T., Electrochemical tests with copper/brass radiator tube
materials in coolants, SAE 2001-01-1754.
5. Ainali M., Korpinen T. and Forsn O., External corrosion
resistance of CuproBraze radiators, SAE 2001-01-1718.
6. Schmoor H., and Nadkarni A. V., Brazing of copper brass
radiators with new brazing pastes, Proc. IBSC 2003.
7. Falken A., Tapper L., Ainali M. and Gustafsson B., The influence
of the brazing parameters on the quality of the heat-exchanger made
by the CuproBraze process. SAE 2003-04-0037.
8. Humpstone G. and J acobson D. M. Principle of Soldering and
Brazing. 1
st
ed. ASM. Materials Park, OH.
9. Soldering Manual. 2 ed. AWS, Miami, FL. 1977.
10. Brazing Handbook. AWS

Disclaimer

Neither Luvata Sweden AB nor Luvata in general will be responsible for any
loss or damage caused by use of any information in this publication, or any
laboratory data or other information provided, including any special,
incidental or consequential damages, even if Luvata has knowledge of the
possibility of the potential loss or damage.

CuproBraze Alliance Members

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BRAZING HANDBOOK

Edition #9, November 2009

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