A corrosion-resistant condenser header and its preparation method

Abstract

The invention discloses a corrosion-resistant condenser header, comprising a core material, an outer skin material and an inner skin material covering the core material; the alloy composition of the core material is: ≤0.2wt% Si, ≤0.5wt% Fe, ≤0.05wt% Cu, 1-1.5wt% Mn, ≤0.1wt% Zn, 0.05-0.2wt% Ti, ≤0.1wt% La, ≤0.1wt% Ce, and the rest is aluminum and unavoidable impurities ; The alloy composition of the outer skin material is: 7.2‑10wt% Si, ≤1wt% Fe, 0.7‑1.5wt% Zn, ≤0.1wt% Ce, ≤0.1wt% Y, and the rest is aluminum and inevitable impurities; the alloy composition of the inner skin material is: 4.5‑5.5wt% Si, ≤1wt% Fe, 0.5‑1.0wt% Cu, ≤0.1wt% Sc, and the rest is aluminum and inevitable impurities. The condenser header has a weld structure at the welding position, and the weld structure includes a welding end A and a welding end B, and an angle c is provided between the welding end A and the welding end B. The present invention effectively avoids the problems of pores in the weld and loose welding, and at the same time, the optimized header material improves the welding strength and corrosion resistance of the condenser.

Description

Technical Field

[0001] The invention relates to the technical field of automobile air-conditioning condensers, and in particular to a corrosion-resistant condenser header and a preparation method thereof. Background Art

[0002] The header is the core component of the parallel flow condenser. It is welded to the ends of multiple flat tubes, forming the internal path for the refrigerant circulation. The header is also welded to the condenser bracket. The welding position bears the external force when the condenser is fixed. The condenser is located outside the front end of the car, which requires the header itself and each welding position of the header to have high strength and corrosion resistance.

[0003] Commonly used rolled header sheet materials, such as 3003 aluminum alloy core materials and 4343 aluminum alloy skin materials, can exhibit problems such as excessive porosity, insufficient surface cladding melting, and weak welds in the overlapped welds and other weld locations. Consequently, welds are less resistant to long-term salt solution corrosion under complex operating conditions. Salt solution corrosion is particularly prevalent in coastal areas and areas where extensive deicing agents are used in winter. As corrosion occurs, the strength and airtightness of welds decrease. Summary of the Invention

[0004] The object of the present invention is to provide a corrosion-resistant condenser header and a preparation method thereof, wherein the weld structure thereof is conducive to the flow of flux and the melting of the header surface skin material, while optimizing the alloy composition of the 3 series core material and the 4 series skin material, thereby improving the welding strength and corrosion resistance of the header rolled weld and other welding positions.

[0005] To achieve the above object, the present application proposes a corrosion-resistant condenser header, comprising a core material, and an outer skin material and an inner skin material covering the core material; the alloy composition of the core material is: ≤0.2wt% Si, ≤0.5wt% Fe, ≤0.05wt% Cu, 1-1.5wt% Mn, ≤0.1wt% Zn, 0.05-0.2wt% Ti, ≤0.1wt% La, ≤0.1wt% Ce, and the rest is aluminum and unavoidable impurities; the alloy composition of the outer skin material is: 7.2-10wt% Si, ≤1wt% Fe, 0.7-1.5wt% Zn, ≤0.1wt% Ce, ≤0.1wt% Y, and the rest is aluminum and unavoidable impurities; the alloy composition of the inner skin material is: 4.5-5.5wt% Si, ≤1wt% Fe, 0.5-1.0wt% Cu, ≤0.1wt% Sc, and the rest is aluminum and unavoidable impurities.

[0006] Furthermore, the condenser header has a weld structure at the welding portion, wherein the weld structure includes a weld end A and a weld end B, and an angle c is provided between the weld end A and the weld end B.

[0007] Furthermore, the inclined surface of the welding end B covers the inclined surface of the welding end A, and there is a gap between the two inclined surfaces.

[0008] Furthermore, when the condenser header is welded into the furnace, the gap opening is ensured to face upwards.

[0009] The present invention also provides a method for preparing a corrosion-resistant condenser core, comprising:

[0010] Step 1: Determine the upward direction of the condenser core when it is put into the furnace for welding;

[0011] Step 2: Assemble the header, flat tubes, fins, pipes, and brackets to form the condenser core, ensuring that the header weld angle c is facing upward when entering the furnace for welding;

[0012] Step 3: Spray flux on the assembled condenser core, and the flux flows into the header weld angle c;

[0013] Step 4: The condenser core is put into the furnace for brazing. At a temperature of 590℃-600℃, the flux remaining in the corner c of the header weld can promote the melting of the header skin material, thereby welding the welding end A and the welding end B together.

[0014] Compared with the prior art, the above technical solution adopted by the present invention has the following advantages: the present invention provides a structure that is conducive to the retention of flux on the surface of the manifold, promotes the melting of the manifold skin material, effectively avoids the problems of pores in the weld and loose welding, and at the same time, the optimized manifold material improves the welding strength and corrosion resistance of the condenser. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 Shown is a schematic diagram of the condenser header structure of the present invention;

[0016] Figure 2 Shown is a schematic diagram of the weld structure of the present invention;

[0017] Figure 3 The figure shows the structure diagram of the condenser header of the present invention when it is put into the furnace;

[0018] Figure 4 Shown is a schematic diagram of the condenser core structure of the present invention;

[0019] Figure 5 The figure shows the schematic diagram of the welding position of the flat tube and the header of the present invention;

[0020] Figure 6 The figure shows the welding position of the bracket and the header of the present invention;

[0021] Figure 7 Shown is a schematic diagram of the welding position of the pipeline and the header of the present invention.

[0022] Explanation of the serial numbers in the figure: 1. Outer material; 2. Core material; 3. Inner material; 4. Manifold; 5. Bracket; 6. Fin; 7. Pipeline; 8. Flat tube. DETAILED DESCRIPTION

[0023] In order to make the purpose, technical solutions and advantages of this application more clearly understood, this application is further described in detail below with reference to the accompanying drawings and examples. It should be understood that the specific embodiments described herein are only used to explain this application and are not intended to limit this application. That is, the embodiments described are only part of the embodiments of this application, not all of them.

[0024] Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the present application for protection, but merely represents selected embodiments of the present application. Based on the embodiments of the present application, all other embodiments obtained by those skilled in the art without making any creative efforts shall fall within the scope of protection of the present application.

[0025] Unless otherwise specified, the experimental methods used in the following examples are conventional methods.

[0026] Example 1

[0027] like Figure 1 As shown, the present application provides a corrosion-resistant condenser header, which specifically includes a core material, and an outer skin material and an inner skin material covering the core material; the alloy composition of the core material is: 0.2wt% Si, 0.5wt% Fe, 0.05wt% Cu, 1% Mn, 0.1wt% Zn, 0.05wt% Ti, 0.1wt% La, 0.1wt% Ce, and the rest are aluminum and inevitable impurities; the alloy composition of the outer skin material is: 10wt% Si, ≤1wt% Fe, 0.7wt% Zn, 0.1wt% Ce, 0.1wt% Y, and the rest are aluminum and inevitable impurities; the alloy composition of the inner skin material is: 5.5wt% Si, 1wt% Fe, 0.5wt% Cu, 0.1wt% Sc, and the rest are aluminum and inevitable impurities.

[0028] like Figure 2 As shown, the condenser header has a weld structure at the welding position, and the weld structure includes a welding end A and a welding end B. The outer side of the welding end A has an acute angle a, and the inner side of the welding end B has an acute angle b. The inclined surface of the welding end B covers the inclined surface of the welding end A, and there is a gap between the two inclined surfaces, which is the angle c.

[0029] like Figure 3 As shown, when the condenser header is welded into the furnace, ensure that the gap opening is facing upwards.

[0030] like Figure 4 As shown, the present invention also provides a method for preparing a corrosion-resistant condenser core, comprising:

[0031] Step 1: Determine the upward direction of the condenser core when it is put into the furnace for welding;

[0032] Step 2: Assemble the header, flat tubes, fins, pipes, and brackets to form the condenser core, ensuring that the header weld angle C is facing upward when entering the furnace for welding;

[0033] Step 3: Spray flux on the assembled condenser core, and the flux flows into the header weld angle c;

[0034] Step 4: The condenser core is put into the furnace for brazing. At a temperature of 590℃-600℃, the flux remaining in the corner c of the header weld can promote the melting of the header skin material, thereby welding the welding end A and the welding end B together.

[0035] Example 2

[0036] The difference from Example 1 is that the alloy composition of the core material is: 0.15wt% Si, 0.4wt% Fe, 0.03wt% Cu, 1.5wt% Mn, 0.08wt% Zn, 0.2wt% Ti, 0.09wt% La, 0.07wt% Ce, and the rest are aluminum and inevitable impurities; the alloy composition of the outer skin material is: 7.2wt% Si, 0.95wt% Fe, 1.5wt% Zn, 0.09wt% Ce, 0.08wt% Y, and the rest are aluminum and inevitable impurities; the alloy composition of the inner skin material is: 4.5wt% Si, 0.98% Fe, 1.0wt% Cu, 0.06wt% Sc, and the rest are aluminum and inevitable impurities.

[0037] Example 3

[0038] The difference from Examples 1 and 2 is that: the alloy composition of the core material is: 0.18wt% Si, 0.48wt% Fe, 0.04wt% Cu, 1.2wt% Mn, 0.07wt% Zn, 0.1wt% Ti, 0.06wt% La, 0.05wt% Ce, and the rest are aluminum and inevitable impurities; the alloy composition of the outer skin material is: 9wt% Si, 0.8wt% Fe, 1wt% Zn, 0.07wt% Ce, 0.09wt% Y, and the rest are aluminum and inevitable impurities; the alloy composition of the inner skin material is: 5wt% Si, 0.8% Fe, 0.8wt% Cu, 0.07wt% Sc, and the rest are aluminum and inevitable impurities.

[0039] like Figure 5-7 As shown, there are schematic diagrams of the welding positions of the header and flat tubes, brackets and pipelines, disassembling the condenser core after brazing, and making resin blocks at the welding positions of the header and various parts. It is observed that there are no cracks in the welds, and the surface pores, porosity and inclusion ratios are less than 20%.

[0040] The foregoing descriptions of specific exemplary embodiments of the present invention are for purposes of illustration and description. These descriptions are not intended to limit the invention to the precise forms disclosed, and it is apparent that many variations and modifications are possible in light of the foregoing teachings. The exemplary embodiments have been selected and described for the purpose of explaining the specific principles of the invention and their practical application, thereby enabling those skilled in the art to realize and utilize a variety of exemplary embodiments of the invention and various options and modifications. The scope of the invention is intended to be defined by the claims and their equivalents.

Claims

1. A method for preparing a corrosion-resistant condenser core, characterized in that: The condenser core includes a header, flat tubes, fins, pipes, and brackets; the header has a weld structure at a welding position, the weld structure including a weld end A and a weld end B, and an angle c is formed between the weld end A and the weld end B; the method includes: Step 1: Determine the upward direction of the condenser core when it is welded into the furnace, and ensure that the angle c of the header weld is facing upward; Step 2: Assemble the header, flat tubes, fins, pipes, and brackets to form the condenser core, ensuring that the header weld angle c is facing upward when entering the furnace for welding; Step 3: Spray flux on the assembled condenser core, and the flux flows into the header weld angle c; Step 4: The condenser core is brazed in a furnace. At a temperature of 590-600°C, the flux remaining in the header weld angle c can promote the melting of the header material, thereby welding the welding end A and the welding end B together. The manifold comprises a core material, and an outer skin material and an inner skin material covering the core material; the alloy composition of the core material is: 0.15-0.2wt% Si, 0.4-0.5wt% Fe, 0.03-0.05wt% Cu, 1-1.5wt% Mn, 0.07-0.1wt% Zn, 0.05-0.2wt% Ti, 0.06-0.1wt% La, 0.05-0.1wt% Ce, and the rest is aluminum and inevitable impurities; the outer skin material The alloy composition of the outer material is: 7.2-10wt% Si, 0.8-1wt% Fe, 0.7-1.5wt% Zn, 0.07-0.1wt% Ce, 0.08-0.1wt% Y, and the rest is aluminum and inevitable impurities; the alloy composition of the inner skin material is: 4.5-5.5wt% Si, 0.8-1wt% Fe, 0.5-1.0wt% Cu, 0.06-0.1wt% Sc, and the rest is aluminum and inevitable impurities.

2. The method for preparing a corrosion-resistant condenser core according to claim 1, characterized in that: The inclined surface of the welding end B covers the inclined surface of the welding end A.

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