18 th month meeting, paris, 20 th may, 2010
DESCRIPTION
18 th month Meeting, Paris, 20 th May, 2010. WPB2.3 Exhaust Heating/Catalyst concepts Heat exchanger manufacturing Delphi Thermal. ECOCAT Catalytic coating application. Delphi tasks and interfaces with its partners. USTT Heat exchanger concept definition and dimensioning/simulation. - PowerPoint PPT PresentationTRANSCRIPT
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
11818thth INGAS meeting, Paris, 20 INGAS meeting, Paris, 20thth May 2010 May 2010
18th month Meeting, Paris, 20th May, 2010
WPB2.3Exhaust Heating/Catalyst concepts
Heat exchanger manufacturing
Delphi Thermal
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
21818thth INGAS meeting, Paris, 20 INGAS meeting, Paris, 20thth May 2010 May 2010
Delphi tasks and interfaces with its partners
Brazing technology
Laser welding technology
USTT Heat exchanger concept definition and
dimensioning/simulation
KATCONCaning manufacturing, insulation, sensors
DELPHIHeat exchanger concept adaptation and its
manufacturability
ECOCATCatalytic coating application
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
31818thth INGAS meeting, Paris, 20 INGAS meeting, Paris, 20thth May 2010 May 2010
Heat exchanger description
Inflow
Outflow
30050
50
0.15 mm
0.15 mm
2.9 mm
Male plate
Tube
Female plate
Tube forming
Fins
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
41818thth INGAS meeting, Paris, 20 INGAS meeting, Paris, 20thth May 2010 May 2010
Technical challenge
• What is the main constraint?– Thermal inertia – Needs to reduce it to improve the efficiency during the cold
start
• Need to reduce the material thickness of tubes and fins.
– High temperature – The heat exchanger has to resist against thermal stress
• What is the difficulty?– Need to identify the lowest material thickness for which brazing is still possible
in accordance with product requirements
– Need to develop the brazing process
– Maintain the core straight without gas leak
Need for development work
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
51818thth INGAS meeting, Paris, 20 INGAS meeting, Paris, 20thth May 2010 May 2010
Work performed
1. Development work– Brazing process development
• Define quantity and BFM (Braze Filler Metal) type
• Braze trials to controlling diffusion of the BFM into the base metal– Define the right braze furnace temperature/time profile – Cross-sectional photo-micrographs: understand the braze joint depth
and base metal dissolution
– Tooling development• Forming the male and female plates to achieve 2.9 mm of cavity
• Build a new stack fixture (device which maintains and compress the stacked core during the brazing in the furnace)
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
61818thth INGAS meeting, Paris, 20 INGAS meeting, Paris, 20thth May 2010 May 2010
Work performed since the 12th Month meeting
2. Manufacturing work: Main steps of the manufacturing process– Cut the fins and plates by EDM wire cutting
– Form the plates
– Fit the fins to the plates
– Clean the fins and plates
– Apply BFM (Braze filler Metal) to the plates
– Assemble stack and compress it with the fixture
– Braze the stack in the vacuum furnace
– Leak check
– Machining the headers
– Assemble the heat exchanger core with the headers
– Apply BFM and maintain the assembly with the fixture
– Braze the stack in the vacuum furnace
– Leak check
Pla
tes
and
fin
s as
sem
bly
Hea
der
s as
sem
bly
The manufacturing of the heat exchanger core is completed
Unit for laboratory testing
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
71818thth INGAS meeting, Paris, 20 INGAS meeting, Paris, 20thth May 2010 May 2010
168 mm
100 mm
Engine test unit
50 mm
Laboratory unit
50 mm
Need for more heat transfer surface
Heat exchanger for engine test bench
outflow
outflow
inflow
inflow
outflow U turn
• Build heat exchanger for the engine test bench – Need for more catalytic and heat transfer surface than the laboratory unit
• Solution: Build 4 units with 27 channels and assemble them together
– Timing:• The work started on week 11• The work completed on week 19
84 mm
50 mm
Laboratory unit
50 mm
Engine bench unit
84 mm
50 mm
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
81818thth INGAS meeting, Paris, 20 INGAS meeting, Paris, 20thth May 2010 May 2010
Heat exchanger for engine test bench
outflow
outflow
inflow
inflow
Fiber Ceramic
Fiber Ceramic
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
91818thth INGAS meeting, Paris, 20 INGAS meeting, Paris, 20thth May 2010 May 2010
Heat exchanger for engine test bench
Side view
Top view
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
101818thth INGAS meeting, Paris, 20 INGAS meeting, Paris, 20thth May 2010 May 2010
Heat exchanger for engine test bench
Front view(Inflow)
Back view(U turn area)
Welding
Welding
Welding
The headers of the 4 units will be welded by Katcon