Converting Cold Plate from Dip Brazing to Vacuum Aluminum Brazing
When a client approached California Brazing with a problem related to the aluminum dip brazing process, we rose to the challenge. As a result of corrosion from trapped salts caused by the aluminum dip brazing process, we decided to examine the product design and manufacturing process so that the component could be properly brazed using the vacuum aluminum brazing process. The conversion was intended to eliminate the corrosion issue, thus enabling a longer product life cycle.
Once the conversion to vacuum aluminum brazing was complete, our client’s problem was solved. Because of their positive experience with California Brazing, the client decided to outsource the complete manufacturing process. We are now responsible for design verification, purchasing, machining, clean room assembly, brazing, inspection, testing, and other special processes.
To learn more about the conversion process, please see below or contact California Brazing .
Aluminum Dip Brazing to Vacuum Aluminum Brazing Cold Plate Specifications:
| Challenge: | Customer is experiencing corrosion from entrapped salts related to the Aluminum Dip Braze Process. California Brazing will make recommendations on product design and manufacturing processes that will allow the assembly to be Vacuum Aluminum Brazed. This conversion will eliminate the corrosion issue that the customer is experiencing, thus allowing for a longer product life cycle. |
| Results / Conclusion: | The conversion to Vacuum Aluminum Brazing was successful. As a result of their experience with California Brazing, the customer also chose to outsource the complete manufacturing process. California Brazing is now responsible for design verification, purchasing, machining, clean room assembly, brazing, inspection, testing, and other special processes (plating, anodizing, and NDT). |
| Customer Testing Requirements: | Visual Inspection / Helium Leak Testing / 100% Dimensional Inspection / Unique Part Identification / Final Packaging |
| Customer Documentation Requirements: | Testing Reports / Certificates of Conformance |
| Testing Specifications: | AWS C3.3 |
| Industries: | Aerospace |
| Application: | Heat Exchanger / Cold Plate for Commercial Aircraft |
| Base Materials: | Aluminum |
| Base Material Grades: | 6061 Aluminum |
| Process: | Vacuum Aluminum Brazing |
| Vacuum Level: | 10-6 Torr Range |
| Backfill Media: | Nitrogen |
| Backfill Gas Dewpoint: | -90°F (minimum) per CGA G-10.1 2008 |
| Backfill Gas Purity: | 99.999% mole (minimum) per CGA G-10.1 2008 |
| Process Specifications: | AWS C3.7M/C3.7:2005 |
| Pyrometry and Instrumentation Calibration: | AMS 2750D (+/- 5°F) |
| Vacuum Furnace Leak-Back Requirements: | 2 micron per hour (maximum) |
| Quality System Requirements: | ISO9001:2008 / AS9100B |
| Approvals Required: | Customer / Prime Aerospace Contractor |
