Water tank, threaded inserts and cooling channels
First I removed the tank and looked at the soldered channels and solder joints. The 65 mm radiator offers 3 rows, so the choice was quite easy. The radiator had already been used, so I lasered away the residue before taking the measurements. So it’s also clear that I can’t write anything about flushing in the factory. But I assume there would have been nothing conspicuous there either. Let’s first take a look at the cooling channels, whereby these flat tubes were produced using the folded solder process. This saves costs.
This special process, also known as seam brazing, is a method of joining thin brass tubes that is characterized by a combination of low working temperature and effective sealing. First, the pipe ends must be thoroughly cleaned and degreased to remove any impurities or oxides that could affect the adhesion of the solder. A flux is then applied to the surfaces to be joined to prevent oxidation during heating and to promote wetting of the metal by the molten solder.
The solder, often in the form of solder wire or paste, is placed at the joint. This is then heated with a suitable heat source. The temperature must be sufficient to melt the solder, but must not damage the brass. The molten solder flows into the gap between the pipes by capillary action. After soldering, the joint must cool and solidify, ensuring that there is no movement during the cooling process to ensure optimum strength and tightness.
After cooling, the solder joint must be cleaned to remove flux and oxidation residues. Finally, the joint is tested for tightness and mechanical strength, either by pressure testing or by visual inspection. The seam soldering process is particularly suitable for thin-walled brass pipes, even in radiators of this type. Both the solder in the seams and that for the duct and tank is made of pure tin, which is pleasing because there are no residues or traces of lead to be found. You can give it the thumbs up. It fits like this.
The cooling channels are slightly harder than the tank and CuZn37 is used. It can be assumed that these come from another supplier of the OEM.
Of course, we are also interested in the material of the tank, including the outer shell and base plate, to which the channels are soldered on the inside. We found CuZn36, which is the most commonly used material, so here too everything was in the green zone. There were no anomalies here either.
All that remained were the cooling fins, which were soldered to the outside of the brass tubes with tin. And yes, this time it is pure copper, which makes sense because of the softness required for bending.
I’ll take care of the rest, such as the threaded inserts, the frame and the summary, on the next page, so please turn the page again!
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