This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Flux Residue and Migration in Charge Air-Cooled Engines
ISSN: 0148-7191, e-ISSN: 2688-3627
Published March 27, 2020 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
Traditionally, most charge air coolers (CACs) have been constructed using the Nocolok aluminum brazing process. The Nocolok process uses flux, some of which remains after the manufacturing process, and migrates through the intake tract to the engine during normal use. This migration and deposition on engine components can cause a variety of issues with engine operation. Currently the only alternative to Nocolok brazed CACs for engines sensitive to flux migration is vacuum brazing, which comes at a significant price increase. In the effort to reduce cost and increase efficiency, there is interest in whether a Nocolok brazed CAC with a reduced amount of flux residue can be successfully applied to flux-sensitive engines. This paper compares the impacts of Nocolok flux migration on engine hardware between a traditional Nocolok brazed CAC versus a Nocolok brazed CAC with a reduced amount of flux residue using a simulated vehicle operation test and its analysis, and examines whether a CAC with reduced flux residue can potentially be used in a flux-sensitive application.
CitationChrzanowski, C., "Flux Residue and Migration in Charge Air-Cooled Engines," SAE Technical Paper 2019-01-5083, 2020, https://doi.org/10.4271/2019-01-5083.
Data Sets - Support Documents
|[Unnamed Dataset 1]|
|[Unnamed Dataset 2]|
|[Unnamed Dataset 3]|
- Häggh, B. and Holmér, E. , “Air-to-Air Charge Air Cooling for Truck Engines,” SAE Technical Paper 790770, 1979, https://doi.org/10.4271/790770.
- Claydon, D.G.W. and Sugihara, A. , “Brazing Aluminum Automotive Heat Exchanger Assemblies Using a Non-Corrosive Flux Process,” SAE Technical Paper 830021, 1983, https://doi.org/10.4271/830021.
- Paquet, A. , “Comparison of Brazing Processes for Aluminum Heat Exchanger Manufacturing,” SAE Technical Paper 931093, 1993, https://doi.org/10.4271/931093.
- Ghassemieh, E. , “Materials in Automotive Application, State of the Art and Prospects,” New Trends and Developments in Automotive Industry (London, InTechOpen, 2011.
- Juan, P.G., Swidersky, H.W., Schwarze, T., and Eicher, J. , “Inorganic Fluoride Materials from Solvay Fluor and Their Industrial Applications,” 2010.
- Schwiegel, M., Meurer, C., and Swidersky, H.W. , “Compatibility of Refrigerant R134a and PAG Oil in the Presence of Post-Braze Flux Residue from Cesium-Containing Fluxes (NOCOLOK® Cs Flux),” in AFC Holcroft-Eighth Annual Invitational Aluminum Brazing Seminar, 2003
- Jeffcoate, C., Ranger, M., Grajzl, J., Yang, B. et al. , “Investigation of Interaction between Coolant Formulations and Flux Loading/Compositions in Controlled Atmosphere Brazed (CAB) Aluminum Surfaces in Heat Exchanger Applications,” Journal of ASTM International 4(1):1-8, 2007, https://doi.org/10.1520/JAI100421.
- Yang, B., Gershun, A., Marinho, F., and Woyciesjes, P. , “Effect of Fluoride on Corrosion of Cooling System Metals in Ethylene Glycol-Based Antifreeze/Coolants,” Journal of ASTM International 3(10):1-10, 2006, https://doi.org/10.1520/JAI100505.
- Tang, Y. , “The Condensation within a CAC-Thermodynamics Analysis,” SAE Technical Paper 2011-01-1168, 2011, https://doi.org/10.4271/2011-01-1168.
- Garcia, J. , “Exhaust Gas Condensate Corrosion Test on Low Pressure Cooling System of Aluminum Brazed EGR, ACAC and WCAC,” SAE Technical Paper 2012-01-1947, 2012, https://doi.org/10.4271/2012-01-1947.
- Cooke, W.E., Wright, T.E., and Hirschfield, J.A. , “Furnace Brazing of Aluminum with a Non-Corrosive Flux,” SAE Technical Paper 780300, 1978, https://doi.org/10.4271/780300.
- Liu, J. , “NOCOLOK Flux and Aluminum Brazing,” SAE Technical Paper 960244, 1996, https://doi.org/10.4271/960244.