Rolled Fins For Automotive Radiators

At Livernois Engineering we work with a variety of industries such as aerospace, automotive, construction, and many more. Also, whatever type of heat exchanger you need to develop, Livernois Engineering can help, contact us today! Rolled fins are a crucial component in automotive radiators, serving as heat exchangers to dissipate heat from the coolant flowing through the radiator tubes. The process of making rolled fins involves several steps, combining precision manufacturing with careful material selection.

Material Selection

• Aluminum is the most commonly used material for fins due to its excellent thermal conductivity, lightweight, and resistance to corrosion.
• Other metals like copper may also be used, especially in high-performance or specialized applications.

Rolling and Slitting

• Rolling: The selected metal sheet (usually aluminum) is first rolled to a specific thickness using precision rollers. This process ensures that the material is thin enough to be formed into fins while maintaining the required strength.
• Slitting: After rolling, the sheet is slit into narrow strips. These strips will eventually be formed into fins.

Corrugation

• The slit strips are fed into a corrugation machine, which shapes them into a zigzag or wavy pattern. This pattern increases the surface area of the fins, enhancing heat transfer.
• The corrugation process is critical, as the dimensions and consistency of the corrugations directly affect the radiator’s performance.

Rolled Fins

• After corrugation, the fins are rolled into their final shape. This process may involve further rolling or shaping to achieve the desired fin profile.
• During rolling, the fin pitch (the distance between adjacent fins) is carefully controlled. The fin pitch is crucial for balancing airflow resistance with heat transfer efficiency.

Cutting to Length

• The continuous rolled fin material is then cut to the required length. This length corresponds to the width of the radiator core.
• The cut fins are inspected for quality and dimensional accuracy.

Assembly

• The fins are then assembled into the radiator core. This process usually involves inserting the fins between the radiator tubes, ensuring good contact between the fins and the tubes for optimal heat transfer.
• The fins may be bonded to the tubes through processes like soldering or brazing, depending on the radiator design and materials used.

Final Inspection and Testing

• The assembled radiator undergoes rigorous quality control checks, including pressure testing, to ensure there are no leaks and that the fins are correctly aligned and securely attached.
• The fins are inspected for any defects, such as tears or improper corrugation, which could impact performance.

Coating and Finishing

• The radiator, including the fins, may receive a protective coating to enhance corrosion resistance. This coating must be thin and uniform to avoid impairing heat transfer.

Packaging and Shipping

• After passing all quality checks, the finished radiators are packaged and shipped to automotive manufacturers or the aftermarket.

Finally, this process ensures that the rolled fins are of high quality, contributing to the efficient operation of automotive radiators.