换热器制造成本动因

决定制造热交换器成本的关键因素

热交换器的价格可能会有所不同。了解为什么可以帮助您削减成本，并仍然获得适当冷却应用程序所需的性能。需求可能会极大地影响制造成本，但这不一定在热或设计工程师的控制之内。但是，您可以通过了解核心和框架材料，接口公差，涂料和其他要求如何影响热交换器的成本来降低成本。通过在设计过程的早期参与热交换器制造商，您将能够识别制造成本驱动力并选择最具成本效益的设计。

核心和框架材料

核心和框架材料规格可以添加团体nificantly to the cost of a heat exchanger. The core, which may consist of tubes, fin, and/or sheet metal, can be manufactured using a variety of metals. The metals most commonly used in heat exchangers are copper, aluminum, and stainless steel. The cost of these metals has risen significantly over the past several years, making their percent of the total heat exchanger cost even greater. Since stainless steel is more expensive than copper or aluminum, it makes sense to opt for copper or aluminum unless your application requires stainless steel. Heat exchangers may also be manufactured using nickel, cupronickel, hastelloy®, inconel®, titanium, or other metals. However, these metals are not used as frequently due to their higher costs.

通常，指定核心的材料，以确保流体路径金属与为应用程序选择的冷却剂兼容。例如，可能会指定不锈钢用于去离子水，而可以指定杯状钢，以与盐水一起使用。还可以根据重量选择热交换器核心材料。铝和钛对于军事和航空航天应用优先，因为这些金属的密度较小。

Core costs can also vary based on the type of heat exchanger selected. Cost variations are due to the different amounts of materials required to make the specific heat exchanger as well as the amount of factory time required to manufacture the part. The least expensive type of heat exchanger to manufacture is a copper tube-fin heat exchanger. Stainless steel tube-fin heat exchangers are more expensive than copper because stainless steel is more expensive by weight, it requires more time to punch, and it must be welded. Like tube-fin heat exchangers, vacuum-brazed flat tube oil cooler heat exchangers are relatively easy to produce. Conversely, the most expensive type of heat exchanger to produce is a vacuum-brazed plate-fin heat exchanger.

其他可以增加成本的热交换器规格是用于将热交换器的框架连接到核心的材料和过程。弹出铆钉是最便宜的选择，其次是螺钉，然后是焊接。螺钉将提供比弹出铆钉更大的强度。扁平管热交换器框架通常用铆钉或焊接连接。通过焊接，结果是一个更强大，更可靠的部分，可以更好地处理冲击和振动。当空间和重量是关注点时，例如用于体重敏感应用（例如空气传播应用）时，焊接也是可取的。焊接消除了使用铆钉的需求，这可以增加重量。此外，铆钉可能需要比焊接更大的热交换器框架，因为铆钉需要大量的金属才能通过并有效地将热交换器框架和芯保持在一起。但是，由于焊接过程中涉及的额外工厂时间，焊接比其他两种方法更昂贵。

Interface Tolerances for Installing Heat Exchangers

After core and frame materials, interface tolerance specifications for mounting and plumbing features are the next biggest cost drivers. For mounting features, the most cost effective approach is to design mounting features into individual sheet metal components. This will yield tolerances ranging from ± 0.03" to ± 0.06" ( ±0.076cm to ± 0.1.52 cm). If tighter tolerances are needed, the product will have to be machined during the final production stages, which will require additional machine time. The heat exchanger is also at risk of contamination from metal chips or coolant from machining, so extra care must be taken. This additional machining step can therefore add significantly to the cost.

正常管道耐受性为铜管鳍热交换器的±1/8“ - ±3/16”（±0.318 cm至±0.476 cm），对于不锈钢和铝产品，铜管鳍热交换器和±1/8“（±0.318 cm）。水管，更昂贵的工具以及人工和检查时间的增加需要公差。现成的管道配件的成本最低，但是，它们的公差较宽。/8英寸（0.953厘米）ID软管，并用夹具固定不需要紧张的公差，因此选择这种类型的配件可能有助于保持低成本。最昂贵的配件选项是定制的机加工配件。

热交换器涂料

Another significant cost driver is heat exchanger coatings for corrosion protection or for cosmetic purposes. Coating for corrosion protection is most common on aluminum heat exchangers, since aluminum corrodes more easily than other metals. There are several types of heat exchanger coatings to minimize corrosion: chemical conversion coating, anodization, e-coating, and painting.

One of the most widely used coating options is chemical conversion coating or chromate conversion coating, also known as "Chem Film", that minimizes surface oxidation. Most government and commercial heat exchanger engineering specifications require that aluminum be chemical conversion coated (per military standard MIL-DTL-5541F, previously MIL-C-5541E).

In addition to Chem Film, another option that can be used to protect aluminum is anodization. Anodizing minimizes corrosion and abrasion by modifying the crystal structure close to the metal surface. It produces a harder part with even greater corrosion protection. However, it is not a common coating and it's more expensive than chemical conversion coating.

提供腐蚀保护的第三种涂层方法称为电子涂料，也称为电沉积或电载。将直流电荷应用于浸入相对充满电的油漆颗粒浴中的金属部分。油漆颗粒被吸引到金属部分，并将油漆沉积在整个表面上的连续膜。这是最昂贵的热交换器腐蚀保护。

Heat exchangers may also be coated with paint for corrosion protection or cosmetic purposes. For example, copper heat exchangers are sometimes painted for aesthetics since uncoated copper may change color over time. For epoxy paint applications, the cost per heat exchanger can range from $10-$200 per heat exchanger. The cost of the paint application will depend not only on the coating itself, but also on the amount of surface area to be coated. Weigh the value of the added corrosion resistance or improved appearance against cost to determine to opt for coating or painting. How long do you want your heat exchanger to last? Will your heat exchanger be visible and how important to your end users is heat exchanger appearance? The appearance of a heat exchanger on equipment in a hospital is likely to be more important than the appearance of a heat exchanger on equipment in a factory.

Heat Exchanger Design and Manufacturing Partnerships

Working with a heat exchanger manufacturer early in the design stage or being flexible on a build to print design will allow for the greatest amount of cost savings. Although the biggest cost driver in heat exchanger manufacturing is annual demand, there are many other factors over which thermal and/or component engineers have some control. Ensure that there is a reason for every specification, as every specification may drive up cost. When core and frame materials, tolerances, and coating specification are outlined, it's important to determine whether they are necessary for the application or not. In addition, it's important to realize that there are many alternatives in heat exchanger design as well as the manufacturing processes used, both of which impact cost.