Self-Bonding Aluminum Alloy Heat Exchanger Fin
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Solution Overview
Problem
The existing methods for manufacturing heat exchangers using aluminum alloy materials face challenges such as high production costs due to the need for brazing filler metals and difficulties in maintaining shape integrity during bonding, especially with thin fin members which are prone to deformation.
Innovation Solution
An aluminum alloy material with specific compositions and microstructures that enables self-bonding under heating without the use of brazing filler metals, utilizing a heat bonding function to maintain shape integrity and reduce production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If brazing filler metal is used for bonding aluminum alloy materials, then strong bonding can be obtained in a short time, but production cost increases
Solution Approach 1:
The invention extracts and removes the brazing filler metal from the bonding process. The aluminum alloy fin material itself is designed with specific composition (Si: 2.0-5.0%, Fe: 0.1-2.0%, Mn: 0.1-2.0%) and microstructure (intermetallic compound particles with specific surface density) to provide self-bonding capability, eliminating the need for separate brazing filler metal and reducing production costs while maintaining bonding strength
Solution Approach 2:
The aluminum alloy fin material is designed to bond with itself or other members through its own material properties rather than requiring external bonding agents. The specific alloy composition and controlled intermetallic compound distribution enable the material to perform its own bonding function when heated,实现 self-service bonding that reduces manufacturing complexity and cost
2Ease of manufacture
If single-layer fin material is used without brazing filler metal, then production cost is reduced, but bonding function is insufficient
Solution Approach 1:
The invention changes the material parameters of the aluminum alloy fin material by controlling the composition (Si: 2.0-5.0%, Fe: 0.1-2.0%, Mn: 0.1-2.0%) and the microstructure (intermetallic compound particle size and distribution). These parameter changes enable the single-layer material to achieve sufficient bonding function through self-bonding when heated, eliminating the need for brazing filler metal while maintaining bonding reliability
Solution Approach 2:
The invention creates a composite microstructure within the aluminum alloy by controlling the distribution and density of intermetallic compound particles (Al-Fe-Si-based and Si-based compounds). This composite microstructure provides both the bonding capability and mechanical strength required for reliable bonding without brazing filler metal
3Strength
If heating temperature is increased to ensure brazing performance, then bonding strength improves, but fin deformation increases
Solution Approach 1:
The invention optimizes the alloy composition parameters (Si: 2.0-5.0%, Fe: 0.1-2.0%, Mn: 0.1-2.0%) and intermetallic compound distribution to achieve a balance where sufficient bonding performance can be obtained at moderate heating temperatures without causing excessive fin deformation. The controlled microstructure allows bonding at temperatures that maintain shape integrity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for efficient bonding of heat exchanger fins without deformation, reducing production costs and ensuring the heat exchanger maintains its shape and strength, even with thin members.
Implementation Method 1
capable of being bonded to another member with its own bonding function without using a brazing filler metal
Data Source
Figure 1~3(d)
Figure 4~5
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AI summary
[Object] An aluminum alloy material is provided which can be bonded as a fin member in a single-layer state of the when a heat exchanger is manufactured, and which is not deformed between before and after bonding. [Solving Means] The present invention provides an aluminum alloy material for a heat exchanger fin, the aluminum alloy material having a heating bonding function in form of a single layer and containing Si: 1.0 % by mass to 5.0 % by mass, Fe: 0.1 % to 2.0 %, and Mn: 0.1 % to 2.0 % with balance being Al and inevitable impurities, wherein 250 pieces/mm2 or more to 7 x 104 pieces/mm2 or less of Si-based intermetallic compound particles having equivalent circle diameters of 0.5 to 5 µm are present in a cross-section of the aluminum alloy material; and wherein 10 pieces/mm2 or more and 1000 pieces/mm2 or less of the Al-Fe-Mn-Si-based intermetallic compounds having equivalent circle diameters of more than 5 µm are present in a cross-section of the aluminum alloy material. The aluminum alloy material may further contain one or more additive elements of Mg, Cu, Zn, In, Sn, Ti, V, Zr, Cr, Ni, Be, Sr, Bi, Na, and Ca.