www.secowarwick.com.plAluminum Brazing ‘SECO/WARWICKis one of the world's most experienced and innovs Brazing Systems installed worldwide. ive furnace manufacturers with over 200 CAB ‘Our commitment to quality products begins in engineering and continues through the complete installation of your system, including aftermarket support. ISO 9001 ce ication in our global manufacturing facilities ensures our high-quality standardsare adhered to throughout the manufacturing process. Controlled atmosphere brazing of aluminum (CAB), using a oncorrosive flux, is the preferred process for manufacturing aluminum heat exchangers, Since entering this field in 1983, SECO/WARWICK has led the development of advanced technology inthe continuous flow brazing process. Capitalizing on over 100, years of furnace design experience, SECO/WARWICK has driven innovations suchas: Improved muffledesign Convection heating technology Continuousatmospherecontrolsystems ACCUBRAZE* CIPLC controls Prioritized heating controlsystems including sinuous loop and gasfiredsystems Energy saving designs system rebuildsandupgrades Feasibility studies So far the main CAB equipment’ customers were the representative of the automotive industry. Now the HVACR (Heating, Ventilation, Air-Conditioning, Refrigeration) industry Istherising, promising market fora CAB process. Index Poge Cas processadvantages 3 The caB process —— = 4s Paditon C48 Furnace 6 Convection Radiation CAB Fumace <> ‘Aetve nly Convecton AB Furace 9 Vacuun Purge CAS Furnace — 0 Arar Services — ” ‘Theseinnovations along with others haveled tothe design of a variety of brazing furnace systems to meet the growing demand for aluminum brazing. Each of these systems provides Unique benefits based on the size and scope of a manufacturer's Individual brazing needs. Custom engineered solutions range from small batch vacuum purge brazing systems and semi-continuous systems for infrequent demand, to large scale continuous based furnace systems designed to deliver efficient, flexible throughput fon a continuous basis, SECO/WARWICK will complete the offering withallthe supportservicesnecessarytoensureasmoothstart-up ofyournew system, CABProcess Advantages ‘The controled atmosphere brazing (CAB) process heats a product to brazing temperatures while maintaining uniform Temperatures within the product in an oxygen-free nitrogen atmosphere. During furnace brazing, a brazing sheet (fig. 1) of. aluminurvsilicon alloy plate (cladding) Is heated to aliquid state and flows to form aluminum joints or filets, A sample ofa filet is shown in figure 2. Figure 3 shows an Al - Si phase diagram giving reference to the different alloys used for CAB brazing with temperatures ofthe liquid phase for each. (Note: AVB is aluminum, vacuum brazing) IIT TN me Condensersatmosphere brazing'sadvantagesinclude: 1 Acceptsaless demanding dimensional fieup 1 Fluxisnoncorrosive,requiringnopost braze cleaning 1 Lesscapitalintensive comparedto vacuum brazing 1 Continuous lowforhigh volume throughput ‘Although heat exchangers such as radiators, condensers, oll coolers, evaporators, heaters, and charge air coolers for the automotive industry dominate current demand, other applications continue to lend themselves 0 aluminum brazing. Consumer applications for air conditioners and various appliances will benefit from this process. Other emerging innovations with unclad braze sheet, micro- extrusion technology, and combination heat ‘exchangers ensure the continuation ofthe CAB process far nto the next decade. The future is bright for smartinvestment in technology that is positioned orstranggrowth, Controlled Atmosphere Aluminum Brazing Systems Figure Figure2 Al-SiPhase Figure Temperature or Alloy Melt Range’c ue vg 1RSOLINE eee 648-657 en 3005 CAB Cote — nnn 643-654 los, 6061 Fitings 638-652 5 hess 4243 ABA AVE Cad 577-612 ses 4045 CAB& AVE Clad 577-599 ST Tas 4047 CRB AVE Clad 577-582 Weight percent silicon wwwsecowarwick.com.pl 3Controlled Atmosphere Brazing Process A fully configured CAB furnace system includes an aqueous washer or thermal degreaser, a fluxer unit, a dry off ‘oven, and the CAB furnace. These systems can be configured in an in-line, a continuous rectangularline, ora U-shaped lineto meet yourplant'sinstallation spacerequirements. 'AThermal Degreaser Oven will hermally emove the lubricating ols present onthe heat exchanger from prior fabrication stages. The assembled and fxtured product will be placedon theoven conveyor for processing. The oven wlltypcally operate at250--300°Cto vaporize the ils. f ight evaporative ols are used in the process the vapors from the [products are oxidized in the combustion chamber. If heavier lubrieating ols are used, an Incinerator at the oven exhaust may be required. The products must thenbe cooled backto ambienttemperaturepriortothe luxing process Thermal Degreaser Thermal degreaser ovens are usually equipped with the equipment forreducing the VOC emission tothe legal mits. The standard solution for this proces isthe thermal incinerator where the ol vapors ‘burned in high temperature. The thermal incinerator‘ usually installed withakind ofheat recovery ystemto reduce the energy consumption. ‘The news solution for reducing the VOC emission is the process ‘based on using the catalytic bea. Although high investing cost the very lowenergy consumption makes thissolution more proftabe, Thermal incinerator Continuous operating CAB furnace with five preheat and seven braze zonesSECOMARWICK's continuous ow tworstation fuxerisbulton aruggedsteelchannelframeand surroundedbystainlesssteel plate ‘The flux applicetor is the latest in design to apply the fx mixture directly to the body art or header as your specifications require. Once applied, a series of adjustable, powerful air knives, positioned over and tothe sides ofthe conveyor sip away the excess fuxtromthe par, ‘The complete system includes necessary pumps, strainers, Inlet and outiet pressure gauges adjustable discharge spray manifold headers and nozzles, two portable stainless steel flux totes with, agitators, a reciculated flux blow-off complete with ar knife, a mist tliminatorand exhaust fan, a variable speed conveyor drive,andallthe necessary piping to make a single connection complete with valves. The unit has 2 prewied control cabinet complete with main sconnectswitchintelocked withthe door for safety. Products requiring internal fluxing will require special consideration depending ontheheat exchanger design Dry Off Oven (CAB Brazing Furnace System Controlled Atmosphere Aluminum Brazing Systems Tred off oven isthe final preparation before brazing ur ovens are built ofan aluminized steel exterior shell and 2 stainless steel internal ska filed with industrial insulation. The oven's internal components are constructed of stainless steel to ensure along working life. Heats provided by electric propane, ora natural gas fue The parts are conveyed int the oven, where they are heated, {and dred prior to brazing. The aris heated in an alr supply chamber {and then forced up though the work The hot aris collected at the top ‘ofthe oven and recirculated backto the heat source for use inthe oven again Allduct workandfansareconstructed of stainlesssteel. The oven temperature, over temperature control, and all pertinent machine controls are mountedinthesystem contol panel The controlled atmosphere brazing process uses 2 noncorrosve fx to reduce the tenacious aluminum oxide over layer that forms on the heat exchanger aluminum surface. ECOAWARWICK ‘CAB furnaces provide the pure nitrogen atmosphere and temperature profile necessary to promote the formation of brazefillts between the fin and tubes and the tube to header joints of aluminum heat exchangers The following furnace designs are avalable to produce @ variety ofparsinargeorsmallvolumeproduction uns Radiation CAB furnace CConvection/Radlation CAB furnace 1 Convection CABfurnace 1 ActiveOnly*CASfurmace 1 Vacuumpurgefurnace Tese brazing furnace systems ate covered in detail in th following pages. Whether you needa small quanttyofprototypepar's ‘oryour business demands high volume production of various sizes and types of aluminum parts, SECOAWARWICK wil custom engineer your controlled atmospherebrazing furnace system wwwsecowarwick.com.pl 5