“We used 10 tons of copper and experimented countless times before we discovered that the opposite of the world's authoritative welding method is the real solution. This idea has created a new product of air-conditioning copper-aluminum connecting pipe.†Materials Science, Ocean University of China Zhao Yue, a senior engineer at the Engineering Research Institute, told reporters.
Zhao Yue said that the thin-walled copper-aluminum tube welding technology, which is called the world-class problem and suitable for industrial production, is the key technology for the aluminum-based copper of the air-conditioner connecting tube. It is not an exaggeration to say that it is a world problem. Many developed countries have studied it for many years. In industry, only copper and aluminum tubes with a wall thickness of 1.0 mm or more can be welded, but there is no breakthrough in welding technology for this thin copper-aluminum tube. “And what we have to solve is the problem of butt welding of thin-walled copper-aluminum pipes that can be used in the production of air conditioners.â€
Traditionally, the refrigeration lines of air conditioning products use copper tubes. However, copper has always been a global shortage of resources, and the price of copper has soared, which has affected the development of the air-conditioning industry. China's aluminum resources are relatively abundant, and the aluminum industry is also relatively developed. Therefore, aluminum-based copper for air-conditioning and refrigeration pipelines has become the trend of the times.
The most critical technology for using aluminum to replace copper is the butt welding of copper and aluminum tubes. To this end, the Qingdao Haiqing Machinery General Factory, which is well-known in the domestic welding industry, has joined forces with China Ocean University to form a research team and take the initiative to undertake the task of this technology.
The reason why thin-walled copper-aluminum welding is called the world's problem is its objective factor. The melting point of copper is 1083 degrees Celsius, the melting point of aluminum is 660 degrees Celsius, which differs by more than 400 degrees Celsius. The result is aluminization, and copper may only be soft. More difficult is that aluminum will naturally form an oxide film on the surface. Due to the cleanliness requirements of the refrigeration line, this oxide film cannot be removed by adding additives, and it is difficult to remove it by physical means. The melting point of the film is up to 2000 degrees Celsius. These three different melting points make the copper-aluminum welding extremely easy to form a virtual solder or even a solder. In the past, some special welding methods, such as explosion welding, diffusion welding, energy storage welding, friction welding, etc., can also be achieved by applying welding aids, but these methods can only complete copper and aluminum tubes of 1.0 mm or more. Welding, or due to high cost and complicated process, is not suitable for industrial production. In some countries, attempts have been made to form welds using copper-aluminum eutectic structures to achieve thin-walled copper-aluminum welding, and extensive research has been carried out for this purpose, but industrial applications have not been realized. The wall of the air-conditioning refrigeration pipeline is very thin, and only the invention of a new welding method to form a thin-walled copper-aluminum tube for industrial welding production can truly achieve the goal of replacing aluminum with aluminum on the air-conditioning refrigeration pipeline.
“In the beginning, we followed the idea of ​​using copper-aluminum eutectic structure to form a weld. We found that the eutectic structure is very fragile due to the thin wall, so the quality of the weld is very poor, even tearing with a tear. It’s down. So we started looking for new ideas,†recalls Zhao Yue.
The new idea comes from a lot of experimentation and analysis.
The welding method adopted by the research team is the commonly used resistance welding method. They began to try to increase the pressure parameters to carry out experiments. Some pipes can be torn off when welded, and some can not be torn off. Through analysis, they found that everything can be The torn, all formed a eutectic structure, but did not tear down, but found no eutectic structure. There are any gaps. Therefore, the "copper-aluminum air-conditioning connecting pipe" project with this welding method as the core of the technology won the national invention patent, and was jointly identified by the Ministry of Science and Technology, the Ministry of Commerce, the AQSIQ and the State Environmental Protection Administration as the national key new product. Currently, this project is applying for international invention patents.
After the “copper-aluminum air-conditioning connecting pipe†produced by Qingdao Haiqing Machinery General Factory adopts thin-wall copper-aluminum pipe welding technology, it has been sold in the market, and its sales price is reduced by half compared with copper pipe, plus its performance, service life and installation convenience. They are superior to pure copper tubes and have quickly won the favor of air conditioner manufacturers. The products are in short supply. At present, most domestic air-conditioning companies have applied this technology product, and air-conditioning companies in Korea and Japan have begun to use this technology product. At the same time, the quality of its products has withstood the test of the market. Since its production in 2004, it has placed nearly 6 million sets of “copper-aluminum air-conditioning connecting pipes†on the market, with a pass rate of 100%.
“As a result, we have won a brand new market.†Zhao Yue said, “Only in the air-conditioning market in China, the annual sales volume of 50 million sets means that there will be nearly 2 billion yuan of copper-aluminum connecting pipe market capacity per year. At the same time, it will reduce the amount of copper used by 50,000 tons."
Zhao Yue said that the thin-walled copper-aluminum tube welding technology, which is called the world-class problem and suitable for industrial production, is the key technology for the aluminum-based copper of the air-conditioner connecting tube. It is not an exaggeration to say that it is a world problem. Many developed countries have studied it for many years. In industry, only copper and aluminum tubes with a wall thickness of 1.0 mm or more can be welded, but there is no breakthrough in welding technology for this thin copper-aluminum tube. “And what we have to solve is the problem of butt welding of thin-walled copper-aluminum pipes that can be used in the production of air conditioners.â€
Traditionally, the refrigeration lines of air conditioning products use copper tubes. However, copper has always been a global shortage of resources, and the price of copper has soared, which has affected the development of the air-conditioning industry. China's aluminum resources are relatively abundant, and the aluminum industry is also relatively developed. Therefore, aluminum-based copper for air-conditioning and refrigeration pipelines has become the trend of the times.
The most critical technology for using aluminum to replace copper is the butt welding of copper and aluminum tubes. To this end, the Qingdao Haiqing Machinery General Factory, which is well-known in the domestic welding industry, has joined forces with China Ocean University to form a research team and take the initiative to undertake the task of this technology.
The reason why thin-walled copper-aluminum welding is called the world's problem is its objective factor. The melting point of copper is 1083 degrees Celsius, the melting point of aluminum is 660 degrees Celsius, which differs by more than 400 degrees Celsius. The result is aluminization, and copper may only be soft. More difficult is that aluminum will naturally form an oxide film on the surface. Due to the cleanliness requirements of the refrigeration line, this oxide film cannot be removed by adding additives, and it is difficult to remove it by physical means. The melting point of the film is up to 2000 degrees Celsius. These three different melting points make the copper-aluminum welding extremely easy to form a virtual solder or even a solder. In the past, some special welding methods, such as explosion welding, diffusion welding, energy storage welding, friction welding, etc., can also be achieved by applying welding aids, but these methods can only complete copper and aluminum tubes of 1.0 mm or more. Welding, or due to high cost and complicated process, is not suitable for industrial production. In some countries, attempts have been made to form welds using copper-aluminum eutectic structures to achieve thin-walled copper-aluminum welding, and extensive research has been carried out for this purpose, but industrial applications have not been realized. The wall of the air-conditioning refrigeration pipeline is very thin, and only the invention of a new welding method to form a thin-walled copper-aluminum tube for industrial welding production can truly achieve the goal of replacing aluminum with aluminum on the air-conditioning refrigeration pipeline.
“In the beginning, we followed the idea of ​​using copper-aluminum eutectic structure to form a weld. We found that the eutectic structure is very fragile due to the thin wall, so the quality of the weld is very poor, even tearing with a tear. It’s down. So we started looking for new ideas,†recalls Zhao Yue.
The new idea comes from a lot of experimentation and analysis.
The welding method adopted by the research team is the commonly used resistance welding method. They began to try to increase the pressure parameters to carry out experiments. Some pipes can be torn off when welded, and some can not be torn off. Through analysis, they found that everything can be The torn, all formed a eutectic structure, but did not tear down, but found no eutectic structure. There are any gaps. Therefore, the "copper-aluminum air-conditioning connecting pipe" project with this welding method as the core of the technology won the national invention patent, and was jointly identified by the Ministry of Science and Technology, the Ministry of Commerce, the AQSIQ and the State Environmental Protection Administration as the national key new product. Currently, this project is applying for international invention patents.
After the “copper-aluminum air-conditioning connecting pipe†produced by Qingdao Haiqing Machinery General Factory adopts thin-wall copper-aluminum pipe welding technology, it has been sold in the market, and its sales price is reduced by half compared with copper pipe, plus its performance, service life and installation convenience. They are superior to pure copper tubes and have quickly won the favor of air conditioner manufacturers. The products are in short supply. At present, most domestic air-conditioning companies have applied this technology product, and air-conditioning companies in Korea and Japan have begun to use this technology product. At the same time, the quality of its products has withstood the test of the market. Since its production in 2004, it has placed nearly 6 million sets of “copper-aluminum air-conditioning connecting pipes†on the market, with a pass rate of 100%.
“As a result, we have won a brand new market.†Zhao Yue said, “Only in the air-conditioning market in China, the annual sales volume of 50 million sets means that there will be nearly 2 billion yuan of copper-aluminum connecting pipe market capacity per year. At the same time, it will reduce the amount of copper used by 50,000 tons."
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