Lord Fin Tube-Nickel-based brazed fin tube
What is Nickel-Based Brazed Finned Tube?
Nickel-based brazed finned tubes represent a sophisticated heat exchange technology where metallic fins are permanently bonded to base tubing using nickel alloy as the brazing material. This advanced manufacturing process creates superior thermal transfer components widely used in radiators, condensers, and various heat exchange equipment across multiple industries.
Brazed Finned Tube Manufacturing Process
The manufacturing of nickel-based brazed finned tubes requires meticulous attention to detail:
Technical Advantage
The nickel-based brazing process creates a metallurgical bond that forms a strong alloy at the joint interface. This results in exceptional thermal conductivity while maintaining mechanical strength at elevated temperatures.
Advanced Nickel-Based Brazing Technology
Nickel-based brazed finned tube technology represents an evolution from traditional high-frequency welding methods. This sophisticated multi-stage process includes:
Process Stages
Material Transformation
During the brazing process, nickel powder melts at 950°C, penetrating the gap between the fin and base pipe. This creates a welded connection forming a durable alloy bond. Additionally, the nickel permeates the carbon steel surface, forming a dense protective alloy layer approximately 0.5 mm thick.
This transformative layer imparts stainless steel-like performance characteristics to ordinary carbon steel, significantly enhancing corrosion resistance and longevity.
Comparative Analysis: Brazed Finned Tube Technologies
| Parameter | Nickel-Based Brazed | Tin-Brazed Copper | Phosphor Bronze Brazed | Nickel-Chromium Brazed |
|---|---|---|---|---|
| Maximum Operating Temperature | 850°C | 400°C | 600°C | 950°C |
| Thermal Conductivity (W/mK) | 50-60 | 380-400 | 100-120 | 45-55 |
| Corrosion Resistance | Excellent | Good | Very Good | Outstanding |
| Pressure Resistance (MPa) | 25-30 | 15-20 | 20-25 | 30-35 |
| Welding Rate | 95-98% | 100% | 100% | 98-99% |
| Primary Applications | High-temp heat exchangers | Standard HVAC systems | Medium-temp industrial | Extreme conditions |
Tin-Brazed Copper Finned Tube Technology
This specialized finned tube variant achieves complete metallurgical bonding between copper tube and copper sheet, resulting in a 100% welding rate. The elimination of contact thermal resistance significantly enhances heat transfer efficiency, making these tubes ideal for prolonged operation under demanding thermal conditions.
Performance Characteristics
Technical Specifications
Base Material: Copper C12200 or equivalent
Fin Material: Copper foil, 0.2-0.5mm thickness
Brazing Material: Tin-based alloys
Operating Temperature: Up to 400°C continuous
Copper Tube Copper Plate Phosphor Bronze Brazed Finned Tube
This advanced finned tube configuration features exceptional thermal performance characteristics with 100% tube-to-sheet welding rate and negligible contact thermal resistance. The technology produces minimal fin wrinkles, uniform spacing, and capability to operate at temperatures exceeding 600°C.
High-Temperature Performance
Phosphor bronze brazed tubes excel in high-temperature environments, maintaining long-term stability even under elevated tube wall temperatures. The unique brazing alloy composition provides enhanced creep resistance and oxidation protection at extreme operating conditions.
Material Advantages
The phosphor bronze brazing material creates a ductile yet strong joint that accommodates thermal expansion differences between components, reducing stress concentrations and extending service life in cyclic temperature applications.
Nickel-Valent Brazed Finned Tubes
Utilizing cutting-edge welding technology, these advanced tubes join the base pipe to the finned tube by melting nickel-chromium alloy solder under precisely controlled high temperatures and reducing atmosphere conditions.
Manufacturing Process
The fins are brazed to the base pipe through an intricate multi-step process:
Performance Metrics
Temperature Range: -200°C to +950°C
Pressure Rating: Up to 35 MPa
Thermal Efficiency: 85-92%
Service Life: 15+ years in aggressive environments
Industrial Applications of Brazed Finned Tubes
| Industry | Primary Applications | Recommended Type | Key Benefits |
|---|---|---|---|
| Petroleum & Chemical | Heat exchangers, reactors, reformers | Nickel-based brazed | Corrosion resistance, high temperature capability |
| Power Generation | Boilers, economizers, superheaters | Nickel-chromium brazed | High pressure tolerance, thermal stability |
| HVAC & Refrigeration | Evaporators, condensers, coils | Tin-brazed copper | Maximized heat transfer, cost efficiency |
| Natural Gas Processing | Coolers, heaters, cryogenic exchangers | Phosphor bronze brazed | Low temperature performance, durability |
| Metallurgical | Furnace heat recovery, air preheaters | Nickel-valent brazed | Extreme temperature operation, oxidation resistance |
Application-Specific Engineering
Nickel-based brazed finned tubes demonstrate exceptional versatility across diverse industrial applications. Their reliability in demanding thermal environments makes them indispensable in sectors requiring efficient heat transfer solutions with long service life and minimal maintenance requirements.
Brazed Finned Tube Technical Performance Data
Thermal Performance Metrics
Heat Transfer Coefficient: 2-3x improvement over bare tubes
Surface Area Enhancement: 5-12x increase depending on fin density
Temperature Efficiency: 85-95% in optimized configurations
Pressure Drop: 10-30% increase compared to plain tubes
Mechanical Properties
Tensile Strength: 350-500 MPa (base material dependent)
Joint Strength: 90-95% of base material strength
Fatigue Resistance: Excellent (>10^6 cycles at design stress)
Thermal Shock Resistance: Superior performance rating