Welding technologies for aluminum roll-bond massive production.

Kurzfassung

An Italian SME offers a set of innovative technologies for the production of high efficiency products for the home refrigeration. The technologies make possible the production of the roll bond without the high investments in rolling mills normally required. The technologies include tools and software custom designed to obtain the best quality of the product in the different required delivery state of the roll bond panels. The company offers the technologies under license agreements.

Details

Company Description

Founded in 1976, the Italian company has begun the activity with the production of evaporators in aluminium with the trial roll-bond for the domestic refrigeration. In few years, thanks to an effective politics of investments, to the continuous innovation of the product and the severe applied standards, the society has become world leader of the market of the evaporators’ roll-bond. The concentration of all the phases of the cycles of workmanship in an only productive reality allows the company to be the unique manufacturer of the sector to have the total control of the trial, from the primary aluminium to the evaporators ready for the line of assemblage of the refrigerator-freezers.

Offer description

The concentration of all the phases of the cycles of workmanship in an only productive reality allows the C. G. A. to be the manufacturing solo of the sector to have the total control of the trial, from the primary aluminium to the evaporators ready for the line of assemblage of the refrigerator-freezers.
The process use pre-bonded plates that contain between two aluminium layers the drawing of the refrigeration circuit ready to be inflated. The inflation process is completely automated by pneutronic systems able to manage high pressure air. (200 bar). The air introduced in the circuit between the pre-bonded plates follow the drawn lanes expanding the layers to pre-determined dimensions. The result is a plate with integrated channels possible to use as heat exchanger, evaporator, and condenser, other...
Furthermore, a proprietary innovative welding technology permits a massive welding method that use a proper alloy melted in one melting pot activated by ultrasounds. The ultrasounds are used in a proper frequency in order to brake the oxide layer normally present on the surface of the aluminium tubes and guarantee a proper sealing of the junction that can be done between tubes (copper or/and aluminium) and panels (roll bond heat exchangers).
The process control avoids the human factor and permits the reduction of the leaks moving the process capability to 6-sigma product.

Innovative Aspects:
The inflating technology makes possible the production of roll bond heat exchangers without the expensive investments in rolling mills, starting with a pre-bonded plate or coil that contain the drawing of the circuit to inflate. The management of the inflating pressure is innovative and use some pneutronic systems.
The welding technology use the special frequency of ultrasounds in order to break the oxide layer on the aluminium surface of the tubes, and obtain a sealed welding of the connection. The layer of welding alloy that covers the external side of the welded tubes or plates is also one excellent protection against corrosion. Make possible the reduction to the lowest level the human factor. - Reduction of needed investments for the same products (1:10) make possible the transfer of the production in low cost countries.
- Reduction of the human factor in a massive production.
- Meaningful reduction of leaks (6 sigma product).
- Real cost reduction produced by rapid and simultaneous process of up to 20 weldings.
- Reduction of material costs (less material thickness required and no steel cores required to sustain the welding).