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CN107073658B - Solder for welding heat exchanger aluminum pipe, and method and structure for joining heat exchanger aluminum pipe using same - Google Patents

Solder for welding heat exchanger aluminum pipe, and method and structure for joining heat exchanger aluminum pipe using same Download PDF

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Publication number
CN107073658B
CN107073658B CN201680002309.1A CN201680002309A CN107073658B CN 107073658 B CN107073658 B CN 107073658B CN 201680002309 A CN201680002309 A CN 201680002309A CN 107073658 B CN107073658 B CN 107073658B
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Prior art keywords
aluminum
solder
heat exchanger
aluminum pipe
welding
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CN201680002309.1A
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Chinese (zh)
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CN107073658A (en
Inventor
中岛孝仁
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Panasonic Intellectual Property Management Co Ltd
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Panasonic Intellectual Property Management Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00Soldering, e.g. brazing, or unsoldering
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00Soldering, e.g. brazing, or unsoldering
    • B23K1/14Soldering, e.g. brazing, or unsoldering specially adapted for soldering seams
    • B23K1/18Soldering, e.g. brazing, or unsoldering specially adapted for soldering seams circumferential seams, e.g. of shells
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/28Selection of soldering or welding materials proper with the principal constituent melting at less than 950 degrees C
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C18/00Alloys based on zinc
    • C22C18/04Alloys based on zinc with aluminium as the next major constituent
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28DHEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D1/00Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
    • F28D1/02Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
    • F28D1/04Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits
    • F28D1/047Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being bent, e.g. in a serpentine or zig-zag
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F21/00Constructions of heat-exchange apparatus characterised by the selection of particular materials
    • F28F21/08Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/007Auxiliary supports for elements
    • F28F9/013Auxiliary supports for elements for tubes or tube-assemblies

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Details Of Heat-Exchange And Heat-Transfer (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)

Abstract

The welding flux for welding the aluminum pipe of the heat exchanger comprises an alloy base metal containing aluminum and zinc and a welding flux with a melting point lower than that of the alloy base metal, wherein when the alloy base metal is 100 mass%, the content of the zinc in the alloy base metal is within a range of 40-75 mass%, the content of the welding flux is within a range of 10-25 mass%, and the welding flux is formed into a wire rod coated with the welding flux by the alloy base metal. This enables the aluminum pipes to be efficiently joined with good quality.

Description

Solder for welding heat exchanger aluminum pipe, and method and structure for joining heat exchanger aluminum pipe using same
Technical Field
The present invention relates to a welding material for welding an aluminum pipe of a heat exchanger used for welding an aluminum pipe made of aluminum or an aluminum alloy, which is provided in a heat exchanger provided in an outdoor unit of an air conditioner, a method for joining the aluminum pipe of the heat exchanger using the welding material, and a joining structure of the aluminum pipe of the heat exchanger.
Background
A heat exchanger provided in an outdoor unit of an air conditioner generally includes a heat transfer tube through which a refrigerant flows and a fin attached to the heat transfer tube. The heat transfer tube is made of copper (or an alloy thereof) (copper tube), and the fin is made of aluminum (or an alloy thereof) (aluminum fin).
A typical manufacturing process of such a heat exchanger includes, for example, a step of arranging and holding a plurality of fins in an aligned manner, mounting a plurality of heat transfer tubes so that the fins penetrate therethrough, and further joining the plurality of heat transfer tubes to each other. As a method of joining heat transfer tubes to each other, joining (welding) by welding is generally used (for example, as a solder for an aluminum pipe, JIS4047 is generally used).
For example, patent document 1 discloses a method for manufacturing a heat exchanger including a step of joining heat exchange tubes by welding. In this manufacturing method, an end portion of a first heat exchanger tube (copper) is subjected to expansion processing (expansion processing step), a ring-shaped brazing material (copper) is inserted into an outer periphery of an end portion of a second heat exchanger tube (copper) (brazing material insertion step), the end portions of these heat exchanger tubes are held in contact with each other (holding step), and the ring-shaped brazing material is melted by heating a contact holding portion of these heat exchanger tubes by a heating device such as a torch (heating step). Thereby connecting (joining) the heat exchange tubes to each other.
However, in the field of heat exchangers, in recent years, aluminum materials (aluminum tubes) have been used for heat transfer tubes as well as fins. For example, in the automotive field, not in the field of air conditioners, aluminum materials (all-aluminum heat exchangers) have been widely used for heat exchangers, heat transfer tubes, and fins. In the production of such an automotive heat exchanger, the welding of aluminum pipes to each other is performed in a heating furnace using a brazing sheet (a sandwich structure of an aluminum alloy and a brazing material).
For example, patent document 2 discloses a method of welding an aluminum material in an inert gas atmosphere furnace without using flux. As described in this document, in order to perform aluminum welding, it is necessary to break the oxide film on the surface of aluminum, and therefore, there are flux welding using a flux and vacuum welding using heating in a vacuum. In the flux welding method, flux is used and heated in an inert gas atmosphere furnace, but there is a concern that a flux residue generated after welding may affect the flux. In addition, in the vacuum welding method, flux may not be used, but the vacuum furnace equipment is expensive and the maintenance cost is high.
The heat exchanger for an automobile is smaller than the heat exchanger for an outdoor unit of an air conditioner, and therefore can be welded by a heating furnace. However, since the heat exchanger for the outdoor unit is larger than the heat exchanger for the automobile, a large heating furnace is required to weld the aluminum pipes in the furnace. In order to realize such a large-sized heating furnace, a large equipment investment is required. In particular, as described in patent document 2, when a vacuum furnace facility is used, the equipment investment is more expensive.
In the case of an outdoor heat exchanger including an aluminum pipe, a method of directly heating a joint portion can be employed as in the case of a heat exchanger including a copper pipe, in order to avoid an increase in cost (see patent document 1). However, in welding aluminum pipes to each other, a through-hole may be formed at the joint due to the flux remaining.
Since the through-hole is clogged with the solidified flux, it cannot be detected as a leakage portion of the aluminum pipe at the time of inspection. However, when the coolant is actually circulated after the inspection, the flux is gradually leached, and thus the coolant leaks from the through hole. Thus, the manufactured heat exchanger for the outdoor unit needs to be inspected in its entirety without performing sampling inspection, and productivity is significantly reduced.
Documents of the prior art
Patent document
Patent document 1: japanese laid-open patent publication No. 10-292992
Patent document 2: japanese patent laid-open publication No. 2013-123749
Disclosure of Invention
The present invention has been made to solve the above problems, and an object of the present invention is to effectively suppress flux remaining when aluminum pipes of a heat exchanger provided in an outdoor unit of an air conditioner are joined to each other by solder, and to effectively join the aluminum pipes with good quality.
In order to solve the above problems, the solder for welding aluminum pipes of a heat exchanger according to the present invention is used for welding aluminum pipes in a heat exchanger having aluminum or aluminum alloy aluminum pipes installed in an outdoor unit of an air conditioner. The solder for welding the aluminum pipe of the heat exchanger comprises: an alloy base material containing aluminum and zinc; and a flux having a melting point lower than that of the alloy base material, wherein when the alloy base material is 100 mass%, the content of zinc in the alloy base material is in the range of 40 to 75 mass%, and the content of the flux is in the range of 10 to 25 mass%. The brazing material for welding the aluminum pipe of the heat exchanger is a wire material in which a flux is coated with an alloy base material.
In the joining method of the heat exchanger aluminum pipes according to the present invention, the welding material for welding the heat exchanger aluminum pipes is supplied to an end holding portion of the aluminum pipes, at which the end of one of the aluminum pipes is inserted into the end of the other of the aluminum pipes and held, and the welding material is melted to join the aluminum pipes to each other.
Further, the joint structure of the heat exchanger aluminum pipe of the present invention is a joint structure in which aluminum pipes are joined to each other with a solder, and has a welded joint portion formed by the solder for welding the heat exchanger aluminum pipe.
According to the above configuration, in the brazing material for welding an aluminum pipe of a heat exchanger, since the temperature difference between the melting point of the brazing material and the melting point of the aluminum pipe is increased, the heating time at the time of joining can be further extended. Therefore, in the joining operation, the flux inside the wire rod is first melted, then, the flux progresses to the alloy base material, and thereafter, the alloy base material outside the wire rod is melted, so that the alloy base material can be easily melted, and the flux can be first leaked by heating for a longer time. This reduces the possibility of flux remaining in the solder connection portion at the joint portion, and thus suppresses the occurrence of defects such as through holes due to the remaining flux. As a result, the aluminum pipes can be efficiently joined with good quality.
In the present invention, the above structure provides the following effects: when aluminum pipes of a heat exchanger provided in an outdoor unit of an air conditioner are joined together by solder, the remaining of flux is effectively suppressed, and the aluminum pipes can be efficiently joined together with good quality.
Drawings
Fig. 1 is a schematic side view showing an example of a heat exchanger aluminum pipe having an expanded pipe portion and an expanded frame portion used in the present invention.
Fig. 2 is a schematic side view for explaining an example of an end holding portion for holding ends of the aluminum pipe shown in fig. 1 together and a structure for supplying the solder to the enlarged frame portion.
Fig. 3A is a schematic process diagram showing an example of a method of joining an aluminum pipe of a heat exchanger according to the present invention, in which a filler material for an aluminum pipe is supplied by a conventional filler material using a wire filler material.
Fig. 3B is a schematic process diagram showing an example of the method of joining the aluminum pipe of the heat exchanger according to the present invention, in which the solder for the aluminum pipe is supplied by the existing solder using the wire solder.
Fig. 3C is a schematic process diagram showing an example of a method of joining an aluminum pipe of a heat exchanger according to the present invention, in which a filler material for an aluminum pipe is supplied by a conventional filler material using a wire filler material.
Fig. 3D is a schematic process diagram showing an example of the method of joining the aluminum pipe of the heat exchanger according to the present invention, in which the solder for the aluminum pipe is supplied by the existing solder using the wire solder.
Fig. 4A is a schematic process diagram showing an example of a method of joining an aluminum pipe of a heat exchanger according to the present invention, in which a filler for an aluminum pipe is supplied by a pre-filler using a ring filler.
Fig. 4B is a schematic process diagram showing an example of a method of joining an aluminum pipe of a heat exchanger according to the present invention, in which a filler for an aluminum pipe is supplied by a pre-filler using a ring filler.
Fig. 4C is a schematic process diagram showing an example of a method of joining an aluminum pipe of a heat exchanger according to the present invention, in which a filler for an aluminum pipe is supplied by a pre-filler using a ring filler.
Fig. 4D is a schematic process diagram showing an example of a method of joining an aluminum pipe of a heat exchanger according to the present invention, in which a filler for an aluminum pipe is supplied by a pre-filler using a ring filler.
Fig. 5 is a diagram showing an X-ray transmission image of a joint structure of heat exchanger aluminum tubes as a result of an example of the present invention and a comparative example.
Detailed Description
The solder for welding an aluminum pipe of a heat exchanger is used for welding the aluminum pipe in a heat exchanger having an aluminum pipe made of aluminum or an aluminum alloy and provided in an outdoor unit of an air conditioner. The welding flux for welding the aluminum pipe of the heat exchanger comprises an alloy base metal containing aluminum and zinc and a welding flux with a melting point lower than that of the alloy base metal, wherein when the alloy base metal is 100 mass%, the content of the zinc in the alloy base metal is within the range of 40-75 mass%, and the content of the welding flux is within the range of 10-25 mass%. The welding flux for welding the aluminum pipe of the heat exchanger is a wire rod coated with the welding flux by the alloy base metal.
According to the structure, in the aluminum solder formed into the wire covered with the flux, the alloy base material does not contain silicon as the prior art, but contains zinc in the range of 40-75 mass%. Thus, the alloy base material can have a melting point higher than that of the flux and lower than that of the conventional aluminum-silicon solder. As a result, the temperature difference between the melting point of the aluminum pipe and the melting point of the solder can be increased, and therefore the heating time at the time of joining can be further extended.
Therefore, in the joining operation, the flux inside the wire rod is first melted and developed into the alloy base material, and thereafter, the alloy base material outside the wire rod is melted, so that the alloy base material can be easily melted, and the flux can be sufficiently leaked by heating for a longer time. This reduces the possibility of flux remaining in the solder connection portion at the joint portion, and thus suppresses the occurrence of defects such as through holes due to the remaining flux. As a result, the aluminum pipes can be efficiently joined with good quality.
In the brazing material for welding an aluminum pipe of a heat exchanger having the above-described structure, the content of zinc in the alloy base material may be in a range of 65 to 75 mass%.
According to the above configuration, the content of zinc in the alloy base material is in the range of 65 to 75 mass%, and therefore the melting point thereof can be further reduced. Therefore, the heating time at the time of joining can be further extended, so that the flux can be more effectively suppressed from remaining, and the aluminum pipes can be joined to each other with good quality and high efficiency.
In the above-structured brazing material for welding an aluminum pipe of a heat exchanger, the alloy base material may further contain silicon.
According to the above configuration, since silicon is further contained in the alloy base material, the fluidity of the solder can be improved, and the quality of the solder can be improved.
In the above-structured brazing material for welding an aluminum pipe of a heat exchanger, the flux may be a metal salt having a melting point lower than that of the alloy base material.
According to the above configuration, since the flux is a metal salt having a low melting point, the flux flows well by heating at the time of bonding. This enables the aluminum oxide film to be removed satisfactorily.
In the above-structured brazing material for welding an aluminum pipe of a heat exchanger, the flux may be an alkali fluoroaluminate.
According to the above structure, since the flux is an alkali fluoroaluminate, the possibility that the flux corrodes aluminum can be avoided.
In the joining method of the heat exchanger aluminum pipes according to the present invention, the welding material for welding the heat exchanger aluminum pipes is supplied to an end holding portion of the aluminum pipes, at which the end of one of the aluminum pipes is inserted into the end of the other aluminum pipe and held, and the welding material is melted to join the aluminum pipes to each other.
According to the above configuration, since the solder of the present invention is used, the melting point is lower than that of the conventional art, and therefore, the heating time at the time of bonding can be extended as compared with the conventional art. This can suppress the occurrence of defects such as through holes due to the residual flux, and therefore, the quality of the joint between the aluminum pipes can be improved, and the efficiency of the joint can be improved.
In the method of joining an aluminum pipe for a heat exchanger having the above-described configuration, the end holding portion may be heated in advance and then the solder may be supplied with the solder in situ, or the end holding portion may be provided with the solder in advance and then heated to melt the solder, and the solder joint portion formed by joining the end holding portion with the melted solder may be heated to leak the flux from the solder joint portion.
According to the above configuration, the aluminum pipes can be joined together satisfactorily by using the brazing material for welding aluminum pipes for heat exchangers of the present invention, regardless of manual work or automatic mechanical work.
In the method of joining the aluminum pipes of the heat exchanger having the above-described configuration, the end holding portion is an expanded pipe portion having an expanded pipe diameter, into which the end of one aluminum pipe is inserted into the end of the other aluminum pipe, and the peripheral edge portion of the end opening of the expanded pipe portion is an expanded frame portion having a further expanded pipe diameter.
According to the above configuration, the enlarged frame portion having a larger diameter than the enlarged tube portion is provided at the end of the one aluminum tube. Thus, for example, in the case of pre-applying solder, the solder disposability is improved, and flux is less likely to overflow from the solder joint portion regardless of pre-applying solder or pre-applying solder. Further, when the solder is heated, heat conduction from the enlarged frame portion occurs, and therefore the solder can be melted more efficiently.
Further, the present invention includes a joint structure in which aluminum pipes are joined to each other by a solder, and the joint structure is a joint structure of heat exchanger aluminum pipes having a structure in which a welded connection portion is formed by a solder for welding the heat exchanger aluminum pipes.
According to the above configuration, since the possibility of flux remaining in the solder connection portion of the bonding structure can be reduced, occurrence of defects such as through holes due to the remaining flux can be suppressed. This enables the realization of a joining structure of aluminum pipes that can be efficiently joined with better quality.
Hereinafter, a representative embodiment of the present invention will be specifically described, but the present invention is not limited to this embodiment.
[ solder for welding aluminum pipe of heat exchanger ]
The solder of the present invention is used for welding an aluminum pipe of a heat exchanger provided in an outdoor unit of an air conditioner. In the present embodiment, for convenience of explanation, the aluminum tubes of the heat exchanger are referred to as "heat exchanger aluminum tubes". Therefore, the solder of the present invention is "a solder for welding an aluminum pipe of a heat exchanger". In the following description, for convenience, the "heat exchanger aluminum pipe" may be simply referred to as "aluminum pipe", and the solder for welding the heat exchanger aluminum pipe may be simply referred to as "solder for aluminum pipe".
As described above, the solder for aluminum pipes of the present invention includes the alloy base material and the flux, and is configured as a wire rod in which the flux is coated with the alloy base material.
The alloy base material contained in the solder for an aluminum pipe contains aluminum (Al) and zinc (Zn) as described above. When the alloy base material is 100 mass%, the zinc content in the alloy base material may be in the range of 40 to 75 mass%, preferably 65 to 75 mass%. If the alloy base material is composed of only aluminum and zinc, the aluminum content is in the range of 25 to 60 mass%, preferably 25 to 35 mass%. When the zinc content is in the range of 40 to 75 mass%, the melting point of the solder for aluminum pipes can be set in the temperature range of 520 to 580 ℃. Further, for convenience of explanation, the melting point of the solder for aluminum pipes to be achieved by adjusting the content of zinc is referred to as "target melting point".
When the content of zinc in the alloy base material is less than 40 mass%, the target melting point of the solder for aluminum pipe exceeds 580 ℃, and the difference in melting point with aluminum cannot be expanded. On the other hand, when the content of zinc exceeds 75 mass%, the target melting point is lowered, not only is close to the melting point of the flux, but also the solder for the aluminum pipe may not spread sufficiently at the time of joining. In this case, as shown in examples described later, the nuggets are generated in the solder for the aluminum pipe, and there is a possibility that a good welded joint cannot be formed. In addition, if the zinc content is 65 mass% or more, the target melting point of the solder for aluminum pipes can be adjusted to 540 ℃. This is preferable because the temperature difference between the melting point of the aluminum pipe and the target melting point of the solder for the aluminum pipe can be further increased.
The alloy base material may contain components (other components) other than aluminum and zinc. Specific types of other components are not particularly limited, and metals that can be mixed with an alloy of aluminum and zinc, etc. can be used as long as they do not interfere with various physical properties required for the weld material for aluminum pipes, particularly, the lowering of the melting point of the alloy base material. Representative examples of the silicon (Si) are silicon (Si). By containing silicon, the fluidity of the solder for aluminum pipes can be improved. The content of silicon is not particularly limited as long as it is within a range in which good fluidity can be provided without preventing achievement of a desired target melting point (the melting point is in a temperature range near the target melting point). In addition, from the viewpoint of not deteriorating the corrosion resistance of the solder for aluminum pipes, the alloy base material preferably does not contain copper (Cu), iron (Fe), and nickel (Ni).
The flux contained in the solder for an aluminum pipe can be selected and used as appropriate from materials having a melting point lower than that of the alloy base material. The content of the flux in the solder for an aluminum pipe may be within a range of 10 to 25 mass%. Specific types of the flux are not particularly limited, and examples thereof include metal salts having a melting point lower than that of the alloy base material. More specifically, for example, cesium fluoroaluminate (Cs) can be mentionedXAlF3+X) Potassium fluoroaluminate (K)XAlF3+X) Alkali metal fluoroaluminates (X1-2) are used. These may be used alone or in combination of two or more.
If the flux is an alkali fluoroaluminate, since it does not contain corrosive elements such as chlorine, it is not necessary to post-clean the formed joint portion. Further, as the flux, aluminum chloride (AlCl) can be applied as long as it does not hinder the post-cleaning3) And the like known chloride-based fluxes.
The solder for an aluminum pipe may be a wire rod in which the flux is coated with the alloy base material, but the specific structure of the wire rod is not particularly limited. The wire rod has an outer diameter of generally 1.6mm, but may be thicker in the range of 1.8 to 2.0mm from the viewpoint of improving workability when joining with the existing solder. Conversely, the outer diameter of the wire may be less than 1.6mm depending on the bonding conditions and the like.
The diameter of the flux portion in the wire rod or the thickness of the alloy base material (the difference between the outer diameter of the wire rod and the diameter of the flux portion) is not particularly limited, and may be within a known range. The method for forming the wire rod is not particularly limited, and any method known in the field of aluminum-based solders can be used as long as a wire rod having a double structure in which a flux is coated on an alloy base material can be manufactured.
[ aluminum pipe of heat exchanger ]
Next, an example of the structure of the aluminum pipe joined by the above-described solder for the aluminum pipe in the present invention will be described specifically with reference to fig. 1 and 2. In the following description, the same or corresponding elements are denoted by the same reference numerals throughout the drawings, and redundant description thereof will be omitted.
The aluminum pipe to be joined in the present invention is a pipe (heat exchanger aluminum pipe) included in the heat exchanger. The heat exchanger aluminum pipe may be made of aluminum or an aluminum alloy, and its application is not particularly limited, but it is generally a heat transfer pipe through which a refrigerant flows. The specific structure of the heat exchanger is not particularly limited, and may be a known structure having a heat transfer tube and a fin. The heat transfer tubes and fins of the heat exchanger of the present invention are both made of aluminum. The heat exchanger may include components other than the heat transfer tubes and the fins, or may include aluminum tubes other than the heat transfer tubes.
In order to join heat exchanger aluminum tubes to each other with a solder for the aluminum tubes, end holding portions are formed which hold respective ends of the heat exchanger aluminum tubes together, and the end holding portions are provided with or supplied with solder. The method of forming the end holding portion is not particularly limited, and the end portions may be held in a state of being engaged with each other. The state of holding the end portions in a fitted manner includes a state in which the end portions are fitted in contact with each other and also includes a state in which the end portions are fitted in non-contact with each other. In addition, from the viewpoint of realizing the end holding portion, a known tool or the like may be used.
In the present embodiment, as an example of a typical configuration of the end holding portion, as shown in fig. 1, a structure is adopted in which an end of one aluminum pipe 11 can be inserted into an expanded pipe portion 11a of an end of another aluminum pipe 12. That is, in the present embodiment, the end holding portion is configured to insert the end of one aluminum pipe 11 into the end of the other aluminum pipe 12. The expanded pipe portion 11a may be a portion having an expanded pipe diameter so that an end of another aluminum pipe 12 can be inserted, and a specific configuration thereof is not particularly limited.
Thus, if the end of one aluminum pipe 11 is formed as the expanded pipe portion 11a, the end holding portion 10 can be formed only by inserting the end of the other aluminum pipe 12 into the expanded pipe portion 11a as shown in FIG. 2. Further, as shown in fig. 1 and 2, when joining the aluminum pipes 11 and 12, one aluminum pipe 11 may be erected and fixed to the end plate 13 with the expanded pipe portion 11a being an upper side.
Here, the expanded pipe portion 11a may have a structure having the same pipe diameter from the root of the expanded pipe portion 11a (a portion connected to the main body of the aluminum pipe 11) to the end opening, but as shown in fig. 1 and 2, the peripheral edge portion of the end opening of the expanded pipe portion 11a is preferably an expanded frame portion 11b having a further expanded pipe diameter.
For example, as shown in fig. 2, when the solder for aluminum pipe of the wire rod (wire solder 20A) is supplied to the end holding portion 10 by the existing solder, the tip end of the wire solder 20A may be positioned on the enlarged frame portion 11 b. In addition, as shown in fig. 2, if the annular aluminum pipe is provided with the solder (ring solder 20B) to the end holding portion 10 by pre-applying the solder, the ring solder 20B can be easily provided to the enlarged frame portion 11B. The present solder addition and solder pre-addition will be described later.
The diameter of the enlarged frame 11b is not particularly limited, and may be larger than the diameter of the enlarged tube 11 a. Although it depends on the pipe diameter of the main body of the aluminum pipe 11, if the pipe diameter of the expanded pipe portion 11a is R1 and the pipe diameter of the expanded frame portion 11b is R2, the difference between the pipe diameters R1 and R2 may be 1.0mm or more, preferably 2.5mm or more. That is, the expanded width Rb of the expanded frame portion 11b as viewed from the expanded pipe portion 11a may be 0.5mm or more, and preferably 1.25mm or more. When the pipe diameter of the main body of the aluminum pipe 11 is R0, R0 may be 6.35mm as a representative example, in this case, R1 may be 6.5mm as a pipe diameter of the expanded pipe portion 11a, and R2 may be 7.5mm or more as a pipe diameter of the expanded frame portion 11b, and preferably 9.0mm or more.
As shown in fig. 2, when joining the aluminum pipes 11 and 12, the end holding portion 10 may be heated by using a heating device (heating means) such as a torch 30, but the specific heating portion is not particularly limited. The representative heating portion may be a supply portion or an installation portion of the solder for aluminum pipe (wire solder 20A, ring solder 20B) of the end holding portion 10 (see the torch 30 positioned in the upper position in fig. 2), but a position below the supply portion or the installation portion of the solder for aluminum pipe may be heated (see the torch 30 positioned in the lower position in fig. 2).
In the present embodiment, an enlarged frame portion 11b is provided in an enlarged tube portion 11a of the aluminum tube 11, and the aluminum tube is supplied with the brazing material to the enlarged frame portion 11b or provided in the enlarged frame portion 11 b. The flux for an aluminum pipe is contained as described above, but the flux needs to be removed as much as possible from the melted flux for an aluminum pipe. In order to sufficiently remove the flux, heating is performed for a long time to such an extent that the aluminum pipe 11 (and the aluminum pipe 12) does not thermally deform. Since the aluminum pipe is supplied to the enlarged frame portion 11b or is provided on the enlarged frame portion 11b with the solder, a method of melting the solder for the aluminum pipe by heat transfer from the enlarged frame portion 11b can be employed from the viewpoint of achieving more stable heating. Therefore, in the present embodiment, as a preferable heating method, a method of heating the lower portion of the enlarged frame portion 11b of the enlarged pipe portion 11a (the vicinity of the lower portion of the end holding portion 10) shown in fig. 2 can be mentioned.
[ method of joining aluminum pipes of Heat exchangers ]
Next, a method of welding the heat exchanger aluminum pipes to each other using the above-described solder for an aluminum pipe, that is, a method of joining the heat exchanger aluminum pipes according to the present invention will be specifically described with reference to fig. 3A to 3D and fig. 4A to 4D.
In the method of joining an aluminum pipe for a heat exchanger of the present invention, the above-described welding material for an aluminum pipe may be supplied to the above-described end holding portion 10 (a portion where the ends of the aluminum pipes 11 and 12 are held in contact with each other), and the welding material for an aluminum pipe may be melted to join the aluminum pipes to each other.
Here, although there is no particular limitation on the method of supplying the solder for the aluminum pipe to the end holding portion 10, a typical example is a method of supplying the solder for the aluminum pipe by adding the solder in place after heating (preheating) the end holding portion 10 in advance, or a method of heating the end holding portion 10 after setting the solder for the aluminum pipe to be pre-solder. The existing solder feeding method can be suitable for manual welding, and the solder pre-feeding method can be suitable for mechanical automatic welding.
The solder for aluminum pipe is supplied in this manner and melted by heating. The melted aluminum tube is fed into the end holding portion 10 between the aluminum tubes 11 and 12 with a welding material to form a welded joint. Here, if flux remains in the solder connection portion, a through hole may be formed in the joint portion. Therefore, by heating the end holding portion 10 for as long as possible, the flux leaks from the solder connection portion. This can sufficiently suppress the occurrence of defects such as through holes.
Fig. 3A to 3D schematically show an example of joining the aluminum pipes 11 and 12 by a manual work by adding a solder. First, as shown in FIG. 3A, the aluminum pipe 12 is inserted into the expanded portion 11a of the aluminum pipe 11 to form the end holding portion 10, and the expanded portion 11a of the aluminum pipe 11 is heated in advance by the torch 30. In this example, as described above, the lower portion of the enlarged frame portion 11b of the enlarged pipe portion 11a (the vicinity of the lower portion of the end holding portion 10) is heated (see fig. 2). Thus, the preheating of the end holding part 10 allows the solder for the aluminum pipe to be efficiently melted.
Thereafter, as shown in fig. 3B, the tip of the wire solder 20A is positioned on the enlarged frame portion 11B of the end holding portion 10, and the solder for the aluminum pipe is supplied by the added solder. The wire solder 20A has a structure in which the flux 22 is covered with the alloy base material 21. Thereafter, as shown in fig. 3C, the wire solder 20A melts. Since the flux 22 has a lower melting point than the alloy base material 21 as described above, the flux 22 inside melts before the surrounding alloy base material 21. The alloy base material 21 is the aluminum-zinc alloy described above, and an oxide film derived from aluminum is formed on the surface thereof. Since the oxide film on the surface of the alloy base material 21 can be removed by coating and spreading the melted flux 22, the alloy base material 21 is melted well and melted and spread at the end holding portion 10.
The alloy base material 21 melted and expanded at the end holding portion 10 flows into the gap formed between the aluminum pipes 11 and 12, but in this state, the flux 22 may remain in the alloy base material 21. Therefore, as described above, the flux 22 in the alloy base material 21 leaks out by continuing the heating by the torch 30. This enables substantial removal of the flux 22 from the alloy base material 21. As shown in fig. 3D, by natural cooling thereafter, a welded joint 23 substantially free of flux 22 can be formed in the gap between the aluminum pipes 11 and 12 at the end holding portion 10.
Fig. 4A to 4D schematically show an example of joining the aluminum pipes 11 and 12 by pre-feeding the brazing material in a mechanical (robot arm or the like) automatic work. First, as shown in fig. 4A, the aluminum pipe 12 is inserted into the expanded pipe portion 11a of the aluminum pipe 11, thereby forming the end holding portion 10, but the ring solder 20B is placed on the expanded frame portion 11B without preheating. The ring solder 20B is also a wire material having a structure in which the flux 22 is covered with the alloy base material 21, similarly to the wire solder 20A.
Thereafter, as shown in fig. 4B, the lower portion of the enlarged frame portion 11B of the enlarged pipe portion 11a (the vicinity of the lower portion of the end holding portion 10) is heated by the torch 30. At this time, the flame of the torch 30 is made strong or weak so that preheating can be performed to a temperature at which the ring weld 20B is meltable and the expanded portion 11a of the aluminum pipe 11 is not deformed. The change in the intensity of the flame may be controlled by a program stored in a controller, not shown.
Thereafter, as shown in fig. 4C, the main heating of the torch 30 is performed, and thereby the annular solder 20B on the enlarged frame portion 11B melts. At this time, as described above, the flux 22 is melted and spread, and the oxide film on the surface of the alloy base material 21 is removed, so that the alloy base material 21 is melted and spread well at the end holding portion 10. Thereafter, the heating of the torch 30 is continued to leak the flux 22 in the alloy base material 21. This enables substantial removal of the flux 22 from the alloy base material 21. By the subsequent natural cooling, as shown in fig. 4D, a welded joint 23 substantially free of the flux 22 can be formed in the gap between the aluminum pipes 11 and 12 at the end holding portion 10.
In this way, in the present invention, an aluminum-zinc alloy base material containing zinc in a range of 40 to 75 mass% is used as the solder for the aluminum pipe, and a flux having a melting point lower than that of the aluminum-zinc alloy base material in a range of 10 to 25 mass% is used as the flux. Therefore, the obtained joint structure of the heat exchanger aluminum pipe has a welded joint portion formed by the above-described solder for an aluminum pipe. This reduces the possibility of flux remaining in the solder connection portion of the joined structure, and therefore, it is possible to suppress the occurrence of defects such as through holes due to the remaining flux. As a result, a joining structure of aluminum pipes that can be efficiently joined with better quality can be realized.
In particular, in the present invention, the solder for an aluminum pipe can be melted at a temperature sufficiently lower than the melting point of the aluminum pipe to be joined. Therefore, the difficulty of soldering is lower than that of the conventional aluminum-silicon solder, workability is improved, and the method is suitable for automation. In this regard, welding of a copper pipe, which is less difficult to weld, will be described as an example.
Conventionally, in a heat exchanger provided in an outdoor unit of an air conditioner, a copper pipe is used as a pipe material such as a heat transfer pipe. When these copper pipes are soldered to each other, a chemically very stable oxide film such as aluminum does not occur in the copper, and therefore, flux is not required to be used for the brazing filler metal. In addition, a phosphorus brazing filler metal (Cu — P), which is a typical brazing filler metal, has a melting point 300 ℃ or more lower than that of a copper pipe. Further, when the copper pipe is heated to a temperature at which the solder melts, the copper pipe turns red by heat radiation. Therefore, for example, when soldering is performed by hand work, the operator can see that the copper pipe is heated to red, and can melt the solder without deforming the copper pipe.
In contrast, in welding aluminum pipes to each other, flux is required to break the oxide film. In addition, the temperature difference between the melting point of a general aluminum solder (Al — Si-based alloy added with silicon) and the melting point of an aluminum pipe is smaller than the temperature difference between the melting point of a copper solder and the melting point of a copper pipe. Further, even when the aluminum pipe is heated to a temperature at which the solder melts, discoloration due to heat radiation, particularly, a change in appearance, is not observed. Therefore, when heating is performed for a long time to avoid the flux remaining during welding, the temperature may reach a high temperature near the melting point of the aluminum pipe, and the aluminum pipe may be deformed. When the heating time is shortened in order to avoid deformation of the aluminum pipe, flux may not flow out of the welded connection portion and may remain. Flux residue causes through-holes to be formed in the solder connection portion.
The through-hole due to the flux remaining is difficult to find by inspection of the joint portion of the aluminum pipe. As a method of inspecting the quality of the aluminum pipe joint, a helium leak test or a water-flooding test is generally used. For example, in the helium leak test, the inside of the joint is made vacuum, and then helium gas is filled from the outside to detect whether helium gas leaks to the outside. The flux is not melted at the time of inspection, and therefore, the through-hole is filled with the flux. Therefore, the leakage of helium gas was not detected, and it was determined that the sealing property existed at the joint. However, when the refrigerant is then circulated through the aluminum pipe, the flux is gradually leached from the through-holes, and the through-holes are opened, thereby causing leakage of the refrigerant. Thus, the manufactured heat exchanger for the outdoor unit needs to be inspected in its entirety without performing sampling inspection, and productivity is significantly lowered.
In contrast, the solder for aluminum pipes of the present invention uses an aluminum-zinc alloy containing zinc in an amount within a range of 40 to 75 mass% as the alloy base material, without using conventional silicon, as described above. Thus, the melting point of the alloy base material can be higher than that of the flux and lower than that of the conventional aluminum-silicon solder. As a result, the temperature difference between the melting point of the aluminum pipe and the melting point of the solder can be increased, and therefore the heating time at the time of joining can be further extended.
Therefore, during the joining operation, the flux inside the wire rod melts and spreads toward the alloy base material, and thereafter the alloy base material outside the wire rod melts, so that the alloy base material is easily melted, and the flux can leak out first by heating for a longer time. This can reduce the possibility of flux remaining in the solder connection portion at the joint portion, and thus can suppress the occurrence of defects such as through holes due to the remaining flux. As a result, the aluminum pipes can be efficiently joined with good quality.
(examples)
The present invention will be described more specifically based on examples and comparative examples, but the present invention is not limited thereto. Various alterations, modifications and changes can be made by those skilled in the art without departing from the scope of the invention.
(example 1)
As shown in fig. 1, an aluminum pipe 11 having a length of 15.5mm, a pipe diameter R0 of 6.35mm, a pipe diameter R1 of 6.5mm in the expanded pipe portion 11a, and a pipe diameter R2 of 7.5mm in the expanded frame portion 11b is fixed to the end plate 13. An end of an aluminum pipe 12 having a pipe diameter R0 of 6.35mm is inserted into an expanded pipe portion 11a of the aluminum pipe 11. Thereby, as shown in FIG. 2, the end holding portions 10 of the aluminum pipes 11 and 12 are constituted.
Further, as a solder for an aluminum pipe, a wire solder 20A formed into a wire rod having a wire diameter of 1.6mm by covering a flux 22 with an alloy base material 21 is prepared. The alloy base material 21 in the wire solder 20A has a composition of 35 mass% of aluminum (Al) and 65 mass% of zinc (Zn), and has a target melting point of 540 ℃. Further, the flux 22 of the wire solder 20A is cesium fluoroaluminate (Cs)XAlF3+XX ═ 1 or 2), the activation temperature was 520 ℃. The weight of the wire solder 20A was 82 mass% of the alloy base material 21 and 18 mass% of the flux 22.
Next, as shown in fig. 3A, the lower portion of the enlarged frame portion 11b of the end holding portion 10 is heated by the torch 30, thereby preheating the end holding portion 10. Thereafter, as shown in fig. 3B, the tip end of the wire solder 20A is positioned on the enlarged frame portion 11B, and the heating of the torch 30 is continued. As a result, as shown in fig. 3C, the wire solder 20A melts, and therefore, the aluminum pipe solder flows between the aluminum pipes 11 and 12 of the end holding portion 10. By continuing the heating, the flux 22 is caused to flow out from the alloy base material 21 as described above.
Thereafter, the heating was stopped and the aluminum tube was naturally cooled, whereby the joint structure of the heat exchanger aluminum tube of example 1 was obtained, in which the welded joint 23 using the solder for the aluminum tube was formed. Fig. 5 shows an X-ray transmission image of the joined structure. In fig. 5, the content of aluminum and zinc (or silicon) in the alloy base material is abbreviated as "%", which means "% by mass".
(example 2)
A joint structure of the heat exchanger aluminum pipe of example 2 was obtained in the same manner as in example 1, except that a material having a composition of 25 mass% of aluminum (Al) and 75 mass% of zinc (Zn) was used as the alloy base material 21 as the wire filler 20A. The target melting point of the alloy base material 21 is 520 ℃. Fig. 5 shows an X-ray transmission image of the joined structure.
Comparative example 1
A heat exchanger aluminum pipe joint structure of comparative example 1 was obtained in the same manner as in example 1, except that a conventional composition material of 88 mass% aluminum (Al) and 12 mass% silicon (Si) was used as the wire filler 20A for the alloy base material 21. The target melting point of the alloy base material 21 was 580 ℃. In comparative example 1, a plurality of joint structures were produced, but the joint structures included a non-defective joint structure and a defective joint structure. Fig. 5 shows X-ray transmission images for the respective acceptable and unacceptable bonding configurations.
Comparative example 2
A heat exchanger aluminum pipe joint structure of comparative example 2 was obtained in the same manner as in example 1, except that a material having a comparative composition of 12 mass% of aluminum (Al) and 88 mass% of zinc (Zn) was used as the alloy base material 21 as the wire filler 20A. The target melting point of the alloy base material 21 is 450 ℃. Fig. 5 shows an X-ray transmission image of the joined structure.
(comparison of examples and comparative examples)
In the X-ray transmission image of the bonding structure shown in fig. 5, a substance having a large atomic number or a substance having a large film thickness has a low X-ray transmittance and is therefore a black image. Cesium originating from the flux 22 or zinc originating from the alloy base material 21 looks darker than aluminum.
From the results of the bonding structures of examples 1 and 2 shown in fig. 5, it is understood that if the solder for aluminum pipe of the present invention is used, a black image derived from the flux 22 or a black image derived from the alloy base material 21 that is not melted is not captured in the X-ray transmission image of the obtained bonding structure. Therefore, no through-hole due to the remaining flux 22 is formed at the joint portion, and no lump or the like of the alloy base material 21 is formed.
Therefore, it is understood that the joint structures of examples 1 and 2 can achieve welding excellent as the conventional joint structure of a non-defective product (non-defective product of comparative example 1). On the other hand, when the conventional aluminum-silicon based solder is used, although good soldering can be achieved as in the acceptable bonding structure of comparative example 1, a black image due to the remaining flux 22 is captured as in the defective product of comparative example 1, and the black image exists over the upper and lower portions of the bonding structure (enlarged tube portion 11 a). Therefore, it is understood that the through-hole is formed in the failed joint structure of comparative example 1, and welding cannot be sufficiently performed.
Further, as is clear from the results of the bonding structure of comparative example 2, even in the case of the aluminum-zinc-based solder, when the content ratio of zinc exceeds 75 mass%, the target melting point of the alloy base material 21 is lower than 520 ℃. Although not shown in the results of fig. 5, even in the case of the aluminum-zinc-based solder, when the content ratio of zinc is less than 40 mass%, the target melting point is equal to or higher than 580 ℃ of comparative example 1, and therefore, a defective product in which through holes are formed may be generated as in comparative example 1.
The present invention is not limited to the description of the embodiments, and various modifications are possible within the scope shown in the claims, and embodiments obtained by appropriately combining different embodiments and the technical means disclosed in the plurality of modification examples are included in the technical scope of the present invention.
Industrial applicability of the invention
The present invention can be widely applied to the field of heat exchangers of outdoor units of air conditioners, particularly to the field of manufacturing heat exchangers having aluminum pipes.
Description of the reference numerals
10 end holding part
11 aluminum pipe
11a expanded pipe section
11b enlarged frame portion
12 aluminum pipe
13 end plate
20A wire solder
20B ring solder
21 alloy base metal
22 welding flux
23 welded connection
30 a torch.

Claims (8)

1. A solder for welding an aluminum pipe of a heat exchanger, which is used for welding the aluminum pipe in a heat exchanger having an aluminum pipe made of aluminum or an aluminum alloy and provided in an outdoor unit of an air conditioner, characterized in that:
comprising an alloy base material containing aluminum and zinc and a flux having a melting point lower than that of the alloy base material,
the zinc content in the alloy base material is in the range of 65-75 mass% and the aluminum content in the alloy base material is in the range of 25-35 mass% when the alloy base material is 100 mass%,
the alloy parent metal contains no copper, iron, and nickel other than unavoidable impurities, and the alloy parent metal contains only the aluminum and the zinc other than the unavoidable impurities,
the content of the flux is within the range of 10 to 25 mass%,
the melting point of the solder for welding the aluminum pipe of the heat exchanger is in the temperature range of 520-540 ℃,
the welding flux for welding the aluminum pipe of the heat exchanger is a wire rod formed by coating the welding flux with the alloy base material.
2. The brazing material for welding an aluminum pipe of a heat exchanger as recited in claim 1, wherein:
the alloy base material further contains silicon.
3. The brazing material for welding an aluminum pipe of a heat exchanger as recited in claim 1, wherein:
the flux is a metal salt having a melting point lower than that of the alloy base material.
4. A brazing material for welding an aluminum pipe of a heat exchanger as recited in claim 3, wherein:
the flux is alkali fluoroaluminate.
5. A method of joining aluminum tubes for a heat exchanger, characterized by:
the aluminum pipe welding solder for a heat exchanger as recited in claim 1 is supplied to an end holding portion of the aluminum pipe which is held with an end of one aluminum pipe inserted into an end of another aluminum pipe, and the aluminum pipes are joined to each other by melting the solder.
6. The method of joining an aluminum pipe for a heat exchanger as recited in claim 5, wherein:
the solder is melted by supplying the solder in the form of a pre-applied solder after heating the end holding portion in advance, or by heating the end holding portion after applying the solder in the form of a pre-applied solder,
and heating a solder joint portion formed by joining the end holding portion with the melted solder, so that the flux leaks from the solder joint portion.
7. The method of joining an aluminum pipe for a heat exchanger as recited in claim 5, wherein:
the end holding portion is formed as an enlarged-diameter expanded pipe portion into which an end of one of the aluminum pipes can be inserted into an end of the other of the aluminum pipes,
the peripheral edge of the end opening of the expanded pipe portion becomes an expanded frame portion whose pipe diameter is further expanded.
8. A joint structure of aluminum pipes for a heat exchanger, which is a joint structure in which the aluminum pipes are joined to each other with a solder, characterized in that:
has a welded joint portion formed by using the welding material for welding an aluminum pipe of a heat exchanger as recited in claim 1.
CN201680002309.1A 2015-10-29 2016-09-09 Solder for welding heat exchanger aluminum pipe, and method and structure for joining heat exchanger aluminum pipe using same Active CN107073658B (en)

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PCT/JP2016/004108 WO2017073003A1 (en) 2015-10-29 2016-09-09 Brazing material for brazing heat-exchanger aluminum pipe, method for joining heat-exchanger aluminum pipe using same, and joint structure of heat-exchanger aluminum pipe

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