heat exchanger aluminum

HEAT EXCHANGER ALUMINUM
YOUR PARTNER IN ALUMINUM SOLUTIONS
We believe that it’s a win-win to enable our customers’ progress.
Quality. Accountability. Integrity. These things are non-negotiable.
When we collaborate with customers to find solutions,
we’re contributing to their success and creating a better world.
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THINK BEYOND
At Aleris, aluminum isn’t just our work — it’s our passion.
It represents opportunity, innovation and game-changing solutions
to create a better world.
With Aleris heat exchanger aluminum,
Aleris provides customers with the
people, the tools and the resources
that they need to realize the value
that aluminum offers.
GLOBAL REACH becomes more important
in business every minute of every day.
Aleris is helping our customers meet
international demand through global assets
such as our newly built world-class rolling
mill in China, which allows us to serve
fast-growing Asian markets.
TECHNICAL PROWESS is what drives our
people. We’re not satisfied with today’s
solutions. By always striving to develop
new and innovative aluminum products for
our customers, we ensure that we’re
providing them the best materials to meet
tomorrow’s challenges today.
SUSTAINABILITY is important to us.
With a safety-focused culture, Aleris looks
after the environment the same way that
we look after our people.
CONSISTENCY in our quality, reliability
and creativity come together to make Aleris
the preferred choice for our customers,
and as a result, a leading global producer
of commercial aluminum plate.
www.aleris.com 3
HEAT EXCHANGER ALUMINUM FROM ALERIS
Aleris is among the world´s leading
suppliers of high-quality aluminum products
for the manufacture of heat exchangers,
and has over 65 years of experience as a
principal supplier to many world-class
industries.
Aluminum is the preferred material for the
increasingly diverse and demanding field of
heat exchanger manufacture, and is used
around the world in many industries,
including the automotive sector, for a
variety of heat exchanger designs.
Aluminum provides a unique combination
of advantages, e.g. its cost, strength,
corrosion life, weight reduction capabilities,
processing and machining characteristics,
and the ability to alloy special material
properties to specific customer applications.
4 www.aleris.com
Our products are being continually
developed and improved. As a result, Aleris
can offer an extensive range of products,
covering a wide range of alloys, tempers,
dimensions and properties.
If you need further data or more urgent
assistance, please contact us using the
information provided at the back of the
brochure or simply visit our website at
www.aleris.com
TECHNICAL CAPABILITIES FOR
CLAD AND CORE MATERIAL
Typical technical capabilities
Customer specific brazing coils and sheets
can be delivered in a large variety of alloy
combinations, clad ratios, thicknesses &
widths, and coil diameters. Our customers
are supported by world class logistics and
strict quality controls (during all steps of our
production). An overview of our production
capabilities is provided opposite.
We can advise you further on process
steps and tempers, if required.
Clad material
%
One side clad / clad ratio
4 - 20
Both sides clad / clad ratio
4 - 15 per side
Clad material
mm
in
Thickness
0.095 - 3.175
0.004 - 0.125
Coil width
25
- 1,280
0.98
- 50.39
Coil inner diameter
250
- 600
9.80
- 23.60
Coil outer diameter (max.)
1,770
Unclad material
mm
in
Thickness
0.095 - 6.4
0.004 - 0.252
69.68
Coil width
15
- 1,650
0.59
- 64.96
Coil inner diameter
152
- 609
6
- 24
Coil outer diameter (max.)
1,676
65.98
Other dimensions, coils and sheets on request
clad
Clad thickness
depending on alloy
combination and
thickness
core
www.aleris.com 5
Clad chemical composition [all data on weight -%]
Alloy
Specification
Aleris
designation
Chemical elements
Si
Fe
Cu
each
total
Mn
Mg
Cr
Zn
Ti
Zr
0.05
0.15
Approx.
melting range
°C
°F
For brazing in controlled atmosphere with / without flux
4343
AA; EN 573-3
Min.
6.8
-
-
-
-
-
-
-
-
-
-
577
Max.
8.2
0.8
0.25
0.10
-
-
0.20
-
-
0.05
0.15
613
1071
1135
8.2
-
-
-
-
-
-
-
-
-
-
577
1071
Hogal 4433
4433
Min.
Max.
8.9
0.8
0.25
0.10
0.035
-
0.2
-
-
0.05
0.15
600
1112
4045
AA; EN 573-3
Min.
9.0
-
-
-
-
-
-
-
-
-
-
577
1071
Max.
11.0
0.8
0.30
0.05
0.05
-
0.10
0.20
-
0.05
0.15
591
1096
Min.
9.0
-
-
-
1.0
-
-
-
-
-
-
554
1029
Max.
10.5
0.8
0.25
0.1
2.0
-
0.20
-
-
0.05
0.15
596
1105
Min.
9.0
-
-
-
1.0
-
-
-
-
-
-
554
1029
Max.
10.5
0.8
0.25
0.10
2.0
-
0.20
-
-
0.05
0.15
596
1105
Min.
9.0
-
-
-
0.45
-
-
-
-
-
-
554
1029
Max.
10.5
0.8
0.25
0.10
0.75
-
0.20
-
-
0.05
0.15
596
1105
4411
Min.
9.0
-
-
-
0.60
-
-
-
-
-
-
554
1029
Max.
10.5
0.80
0.25
0.10
0.80
-
0.20
-
-
0.05
0.15
596
1105
Hogal 4450 2) 4450
Min.
9.0
-
-
-
0.16
-
-
-
-
-
-
577
1071
Max.
11.0
0.30
0.30
0.05
0.25
-
0.10
0.20
-
0.05
0.15
591
1096
Hogal 4470 3) 4470
Min.
11.0
-
-
-
0.15
-
-
-
-
-
-
577
1071
Max.
14.0
0.30
0.30
0.15
0.25
-
0.20
-
-
0.05
0.15
582
1080
Min.
6.8
-
-
-
-
-
0.9
-
-
-
-
577
1071
Max.
8.2
0.8
0.25
0.10
-
-
1.1
-
-
0.05
0.15
605
1121
Min.
9.0
-
-
-
-
-
0.9
-
-
-
-
577
1071
Max.
11.0
0.8
0.30
0.05
0.05
-
1.1
0.2
-
0.05
0.15
591
1096
Min.
-
-
-
-
-
-
-
-
-
-
-
646
1195
Max.
Si + Fe max. 0.55
0.05
0.05
0.05
-
0.05
0.03
-
0.05
0.15
657
1215
-
-
-
-
0.8
-
-
-
-
645
1193
0.10
0.10
0.10
-
1.3
-
-
0.05
0.15
657
1215
For vacuum brazing
4004
4104 1)
4004 mod.
4104 mod.1)
AA; EN 573-3
AA; EN 573-3
4403
Zn containing 6)
Hogal 4437 4) 4437
Hogal 4453 5) 4453
For corrosion protection 7)
1145
7072
AA
AA
Min.
Max.
Si + Fe max. 0.7
1) Bi 0.02 - 0.20%
2) Hogal 4450 is similar to AA4045 + max. 0.25% Mg
3) Hogal 4470 is similar to AA4047 + max. 0.25% Mg
4) Hogal 4437 is similar to AA4343 + 1% Zn
5) Hogal 4453 is similar to AA4045 + 1% Zn
6) Higher Zn concentrations are available on request
7) 3xxx series alloys are also available for corrosion protection on request
Further options on request
6 www.aleris.com
Core chemical composition for tubes, side supports, headers [all data on weight -%]
Alloy
Specification
Aleris
designation
3003
AA; EN 573 - 3
Chemical elements
each
total
Si
Fe
Cu
Mn
Mg
Cr
Zn
Ti
Zr
0.05
0.15
Approx.
melting range
°C
°F
Min.
-
-
0.05
1.0
-
-
-
-
-
-
-
643
Max.
0.6
0.7
0.20
1.5
-
-
0.10
-
-
0.05
0.15
655
1211
1.0
0.20
-
-
-
-
-
-
629
1164
1189
3005
AA; EN 573 - 3
Min.
-
-
-
Max.
0.6
0.7
0.30
1.5
0.6
0.10
0.25
0.10
-
0.05
0.15
654
1209
3103
AA; EN 573 - 3
Min.
-
-
-
0.9
-
-
-
-
-
-
-
640
1184
Max.
0.50
0.7
0.10
1.5
0.30
0.10
0.20
0.10
-
0.05
0.15
655
1211
Hogal 3190
3190
Min.
-
-
0.2
1.0
0.40
-
-
-
-
-
-
629
1164
Max.
0.4
0.70
0.5
1.5
0.70
0.10
0.25
-
-
0.05
0.15
654
1209
Hogal 3527
3527
Min.
0.45
0.34
0.6
0.9
-
0.05
-
-
-
-
-
643
1189
Max.
0.65
0.44
1.0
1.5
0.1
0.15
0.1
0.1
0.05
0.05
0.15
655
1211
Hogal 3529
3529
Min.
0.45
0.34
0.6
0.9
-
0.05
-
-
-
-
-
643
1189
Max.
0.65
0.44
1.0
1.5
0.03
0.15
0.1
0.1
0.05
0.05
0.15
655
1211
Hogal 3532
3532
Min.
-
-
0.5
0.65
0.1
-
-
0.08
-
-
-
643
1189
Max.
0.3
0.5
0.7
1.00
0.3
-
0.10
0.10
-
0.05
0.15
655
1211
Hogal 3534
3534
Min.
-
-
0.5
0.65
-
-
-
0.08
-
-
-
643
1189
Max.
0.3
0.5
0.7
1.00
0.02
-
0.10
0.10
-
0.05
0.15
655
1211
Corus 3536
3536
Min.
-
-
0.80
0.75
0.15
-
-
-
0.05
-
-
Max.
0.3
0.5
1.00
1.00
0.24
0.05
-
0.10
0.15
0.05
0.15
Corus 3537
3537
Min.
0.45
0.34
0.90
1.10
-
0.10
-
-
0.05
-
-
Max.
0.65
0.44
1.10
1.3
0.1
0.25
0.10
0.05
0.15
0,05
0.15
Hogal 3542
3542
Min.
-
-
0.40
0.90
0.20
-
-
0.08
-
-
-
643
1189
Max.
0.10
0.25
0.60
1.2
0.30
0.05
0.05
0.10
-
0.05
0.15
655
1211
0.5
-
0.1
0.5
-
0.05
-
-
0.05
-
-
on request
on request
Hogal 3551
3551
Min.
Max
1.25
0.5
0.6
1.25
0.25
0.20
0.25
0.20
0.20
0.05
0.15
Hogal 3570
3570
Min.
0.45
0.40
0.40
0.70
0.30
-
-
-
-
-
-
616
Max.
0.65
0.60
0.60
0.90
0.40
0.10
0.20
0.20
-
0.05
0.15
654
1209
0.30
-
0.60
1.00
0.27
-
-
-
-
-
-
616
1141
on request
1141
Hogal 3572
3572
Min.
Max.
0.70
0.40
0.90
1.40
0.32
-
0.15
0.05
-
0.05
0.15
654
1209
6060
EN 573 - 3
Min.
0.30
0.10
-
-
0.35
-
-
-
-
-
-
616
1141
Max.
0.6
0.30
0.10
0.10
0.6
0.05
0.15
0.05
-
0.05
0.15
654
1209
6063
AA; EN 573 - 3
Min.
0.20
-
-
-
0.45
-
-
-
-
-
-
616
1141
Max.
0.6
0.35
0.10
0.10
0.9
0.10
0.10
0.10
-
0.05
0.15
652
1206
Some alloys requires a minimum order tonnage for quotation
Further options on request
www.aleris.com 7
Core chemical composition for bare and clad fin stock [all data on weight -%]
Alloy
Specification
Aleris
designation
Chemical elements
Si
Fe
Cu
Mn
Mg
Cr
Zn
Ti
Zr
each
total
0.05
0.15
Approx.
melting range
°C
°F
Zn free
3003
AA; EN 573 - 3
Min.
-
-
0.05
1.0
-
-
-
-
-
-
-
643
1184
Max.
0.6
0.7
0.20
1.5
-
-
0.10
-
-
0.05
0.15
655
1211
Zn containing
3003 + 1.5% Zn
-
Min.
-
-
0.05
1.0
-
-
1.3
-
-
-
-
640
1184
Max.
0.60
0.7
0.20
1.5
-
-
1.5
-
-
0.05
0.15
657
1215
Non heat-treatable - high strength
Corus 3555
3555
Min.
0.7
-
-
0.7
-
-
1.3
-
-
-
-
611
1132
Max.
1.2
0.7
0.5
1.2
0.15
0.1
1.7
0.2
-
0.05
0.15
654
1209
Some alloys requires a minimum order tonnage for quotation
Further options on request
Properties pre and post braze (typical values)
Core alloy
(Comments)
Temper 1)
Gauge
Pre braze tensile property
ASTM B557
Yield
Tensile
Elongation
strength
strength
Rm
A50
Rp0.2
Post braze tensile property 2)
ASTM B557
Yield
Tensile
Free
strength
strength
Corr. Pot.
Rp0.2
Rm
(SCE)
ASTM G69
Sagging
Electrical
resistance 3) conductivity
mm
MPa
MPa
%
MPa
MPa
mV
mm
% IACS
-
Fin stock
AA3003
0.1
Min.
-
140
-
35
100
-710
-
0.3
Max.
>115
180
>1
45
120
-740
-
40.45
H14
0.1
Min.
-
140
-
35
100
-710
-
-
0.3
Max.
>115
180
>1
45
120
-740
-
40.45
3003 + 1.5% Zn
H14
0.1
Min.
-
140
-
35
100
-850
- 4)
-
0.3
Max.
>115
180
>1
45
120
-880
- 4)
40.45
Corus 3555
H16
0.1
Min.
-
185
-
50
125
-725
<15
-
0.3
Max.
>160
220
>0.5
55
145
-745
-
40.4
0.1
Min.
-
140
-
-
-
-740
- 4)
- 4)
0.3
Max.
>130
175
>1
70+
100+
-770
- 4)
- 4)
0.1
Min.
-
130
-
-
-
-740
- 4)
- 4)
0.3
Max.
>100
175
>6
70+
100+
-770
- 4)
- 4)
3103
H14
(low Mg)
(high strength 1.5% Zn)
AA6063
AA6063
H16
H26
1) Other tempers available
2) Braze cycle: 600°C / 3 min.
3) 50 mm overhang. gauge 0.1 mm
4) Available on request
8 www.aleris.com
Properties pre and post braze (typical values)
Core
alloy
Temper 1) Gauge
mm
Pre braze tensile property
ASTM B557
Yield
Tensile
Elongation
strength strength
Rm
A50
Rp0.2
Post braze tensile property
ASTM B557
Yield
strength
Rp0.2
Tensile
strength
Rm
0 days 10 days 20 days 40 days
0 days 10 days 20days
MPa
MPa
MPa
%
MPa
MPa
40days
MPa
Free
corrosion
potential
(SCE)
ASTM G69
mV
Formed components
AA3003
Hogal 3527
Hogal 3532
Hogal 3534
Corus 3537
Hogal 3542
Corus 3547
Corus 3547
Corus 3536
Hogal 3551
Hogal 3572
Hogal 3572
O
O
O
O
O
O
O
H22
O
O
O
H22
-
Min.
-
-
-
35
-
Max.
>35
>125
28
37
1
Min.
-
-
-
50
2
Max.
>35
>145
>17
60
0.3
Min.
-
117
-
-
3
Max.
>45
165
>18
50
0.3
Min.
-
117
-
-
3
Max.
>45
165
>18
48
1
Min.
-
150
-
50
3
Max.
>50
190
>17
65
0.3
Min.
-
117
-
-
3
Max.
>45
165
>18
50
not applicable
-
not applicable
-710
115
not applicable
-740
150
not applicable
-680
160
not applicable
-700
130
not applicable
-680
170
not applicable
-710
130
not applicable
-680
140
not applicable
-710
150
not applicable
-670
165
not applicable
-720
130
not applicable
-685
170
not applicable
-710
1
Min.
-
150
-
50
3
Max.
>50
190
>17
65
150
not applicable
-670
1
Min.
-
175
-
50
3
Max.
>155
235
>8
65
0.3
Min.
-
140
-
55
60
60
60
150
155
160
160
-670
3
Max.
>50
180
>18
60
65
65
65
155
160
165
165
-720
0.5
Min.
-
120
-
45
50
60
65
155
160
165
175
-710
3
Max.
>35
160
>18
50
60
65
70
160
165
175
185
-740
1
Min.
-
150
-
55
60
65
70
155
160
175
190
-710
3
Max.
>50
175
>18
60
65
70
80
160
170
185
200
-740
1
Min.
-
175
-
55
60
65
70
155
160
175
190
-710
3
Max.
>140
235
>8
60
65
70
80
160
170
185
200
-740
-
Min.
-
<200
-
35
-
Max.
>120
-
>1
37
Min.
-
180
-
55
165
not applicable
-720
150
not applicable
-670
165
-720
Tube stock
AA3003
H14
not applicable
115
not applicable
-710
not applicable
-690
not applicable
-680
not applicable
-680
not applicable
-680
not applicable
-685
not applicable
-670
-
H24
0.3
1.0
Max.
>145
235
>5
-
Hogal 3527
H24
0.2
Min.
-
190
-
55
0.3
Max.
Hogal 3532
H24
0.25 Min.
Hogal 3534
H24
0.25 Min.
1
Max.
>145
235
>3
-
Hogal 3542
H24
0.3
Min.
-
165
-
50
1
Max.
Corus 3537
H24
0.25 Min.
Corus 3536
H24
0.25 Min.
>165
265
>3
65
70
75
85
165
175
180
190
-720
Hogal 3572
H24
0.25 Min.
-
200
-
70
90
100
105
190
215
225
235
-710
1.0
>165
265
>3
80
95
105
110
200
225
235
240
-740
1
1
1
Max.
Max.
Max.
Max.
>165
265
>5
60
-
165
-
50
>145
235
>3
-
-
165
-
48
>145
235
>3
-
-
180
-
60
>165
265
>5
70
-
185
-
60
not applicable
130
not applicable
155
not applicable
120
not applicable
130
not applicable
120
not applicable
160
-740
Hogal 3190
180
-720
165
-700
170
-710
140
-710
170
-710
180
65
70
75
155
-720
165
175
180
-670
www.aleris.com
www.aleris.com 9
CORROSION PROTECTION
Aluminum heat exchangers are subject to a
wide range of severe environmental
conditions, e.g. de-icing road salt, grit, acid
exhaust fumes, etc. The heat exchanger can
be protected against aggressive external and
internal corrosion attacks using the principle
of galvanic protection for critical components and through suitable alloy selection.
A less noble (anodic) alloy will corrode
preferentially to a noble (cathodic) alloy
when in contact via a corrosive medium.
This principle can be applied to the
individual components of a heat exchanger
(e.g. tubes, headers, tanks, etc.), and it can
also be applied to the heat exchanger alloy
system itself.
In addition to the galvanic protection
principle, the micro-structure of Aleris’
brazing alloys have been engineered to
improve their corrosion life. This alloy
development process is ongoing through
our continuous R&D activities, and has
to date produced a series of “Long-Life”
alloys, and more recently multiclad
materials.
Corrosion potential [mV]
-680
-690
Hogal 3532
-700
Hogal 3190
-710
-720
-730
0
50
100
depth [µm]
clad
WE CAN ADVISE YOU FURTHER ON
ALLOY SELECTION AND COMPATIBILTIY,
IF REQUIRED.
core
length
10 www.aleris.com
150
Figure 1: Standard alloy AA3003, clad AA4104, cross section [x100].
1ST GENERATION
LONG-LIFE ALLOYS
The special chemical compositions and
thermo-mechanical processing of these
alloys (e.g. Hogal 3190, 3532, 3534, 3542),
have been designed by Aleris to give both
high corrosion performance and high
strength. On brazing Si diffuses from the
clad into the core, where small particles of
α-Al(MnFe)Si precipitate along the clad /
core interface, this band has a corrosion
potential lower than the core and acts to
sacrificially protect it against external
corrosion penetrating through the material
depth. In H24 temper these alloys have
elongated grains after brazing, which are
also advantageous for corrosion, as they
create longer grain boundaries compared
to other material tempers.
ife
Long-L
alloy
Figure 2: Long-Life alloy 3190, clad AA4104, cross section [x100].
2ND GENERATION
AGE HARDENING / HIGH STRENGTH
The use of Cu in these alloys (e.g. Hogal
3572, 3536) creates an additional corrosion
protection mechanism in these material,
after brazing a Cu depleted band, which is
less noble compared to the core material
also protects against external corrosion
penetrating through the material.
ife
Long-L
alloy
Figure 3: Grain structure of Long-Life alloy 3190, grain size ASTM 4 [x100].
3RD GENERATION
“ECO” ALLOYS
Our latest generation of alloys (e.g. Hogal
3551 and 3527) have been designed to
provide an economically optimized solution
between the performance of the 2nd
generation alloys and the cost of the 1st
generation alloys. This has been achieved
by enhancing the chemistry of these
materials to make them both more cost
effective and environmentally friendly,
as they can require less primary (pure)
aluminum in their initial processing.
ife
Long-L
alloy
Figure 4: Microstructure: band of dense α-Al(MnFe)Si precipitates, [x500].
www.aleris.com 11
Global Headquarters
Aleris International, Inc.
25825 Science Park Drive
Cleveland, Ohio 44122 · USA
T +1 216 910 3400
info@aleris.com
European Head office
Aleris Switzerland GmbH
Balz Zimmermann-Straße 7
8058 Zürich Airport · Switzerland
T +41 44 828 1400
info.europe@aleris.com
Plant Koblenz
Aleris Rolled Products Germany GmbH
Carl-Spaeter-Straße 10
56070 Koblenz · Germany
T +49 261 891 7479
Plant Duffel
Aleris Aluminum Duffel BVBA
A. Stocletlaan 87
2570 Duffel · Belgium
T +32 15 30 2111
www.aleris.com
Pictures used by courtesy of
Behr GmbH & Co. KG, Haugg Kühlerfabrik GmbH
and Modine Manufacturing Company.
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© 2014, Aleris Corporation
Issue 5/14 · 1st release