In the manufacturing of their heat exchangers, Thermal Transfer utilizes induction brazing to join copper tubes to a steel manifold. Brazing provides flexibility in the manufacturing process as their units vary in both the size of the tubes, and in the number of rows of tubes that are to be joined.

Preformed rings of Handy One® Flux Cored SILVALOY® 560 (cored with a boron-modified flux) are applied to the copper tubes prior to assembly. No additional flux is required and ascetically superior, leak-free joints are produced when compared to traditional solid wire and flux.

Thermal Transfer has found that their switch to flux cored materials has reduced their leak rate and saved them time and money in their brazing operation. Some advantages they’ve cited include the elimination of a separate fluxing operation as well as their post braze cleaning. Other benefits include a reduction in the amount of filler metal used because the alloy stays confined to the joint area, and improved post-braze operations (fabrication and welding) due to the reduction of flux residue.

Why brazing? Thermal Transfer requires a high quality, cost efficient process in the production of their industrial heat exchangers. The use of flux-cored rings from Lucas-Milhaupt was an ideal fit for their application.

Large copper tube aluminum plate fin heat exchangers for heavy-duty cooling applications are manufactured by Thermal Transfer Products, a ThermaSys Company in Racine, WI.

  1. Handy One® flux cored brazing alloys are ideal for products such as heat
    exchangers because they simplify the brazing process and provide stronger,
    better quality joints.
  2. Flux cored brazing rings are placed onto the copper tubes.
  3. Oval rings provide increased surface area and improved alloy flow.
  4. The brazing flux meets and flows from the internal seam of the brazing ring,
    uniformly coating the base metal around the circumference of the joint.
  5. The brazing alloy has melted, completing the joints.