Heat exchanger testing

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On this page:

Heat exchanger testing – introduction
Heat exchanger ageing tests
Testing internal and external corrosion and erosion of heat exchangers
- Internal corrosion/erosion
- External corrosion
  - Testing the external corrosion resistance of products using a salt chamber
Freon emission tests – leak testing of automotive air conditioning systems
Thermal efficiency
Testing fan characteristics
Metalographic examination of heat exchangers
Resistance to water
Electric fan testing
- Electrical fan durability testing
  - Electric fan blade durability testing
  - Spin to Burst test
Fatigue and durability testing of heat exchangers
- Heat exchanger spigot connector bending tests in a temperature chamber
- Tests of heat exchanger components as well as complete modules

See more:

Cykle ciśnieniowe – Pressure cycles
Testy wibracyjne
Szoki termiczne
Odporność na próżnię – badanie szczelności wyrobu
Pomiary akustyczne w komorze bezechowej
Testy szczelności wyrobów, podzespołów i połączeń
Szczelność helowa – badanie szczelności wyrobu
Testy odporności na ciśnienie rozrywające (Burst tests)
Pomiary termowizyjne wymienników ciepła
Pomiary tensometryczne
Badania produktów naftowych i cieczy eksploatacyjnych
Badania korozyjne

Heat exchanger testing – introduction

We subject heat exchangers to the following test types:

Temperature-based
Pressure-based
Environmental
Vibrational
Acoustic

We conducts tests according to the following norms:

BMW, Fiat, Ford, GM, Jaguar, Mazda, Mercedes, Nissan, PSA, Renault, Volvo, VW, Toyota and others.

We also perform:

Tightness (leak) tests (as well as vacuum tests)
Chip resistance tests
Impact tests
Pin test (pin breaking force)
Chemical resistance tests / ageing tests of plastic products testy
Cleanliness tests (according to norm DIN 8964-1)
Measurements of geometric dimensions
Calcium chloride tests
And other special tests for special customer requests.

We test:

Coolers
Radiator cores
Intercoolers
Oil coolers
Fan blades and fan guards
Condensers
Hoses, pipes, gaskets and seals, etc.

The parameters of the tests presented are only examples; it is possible to change the parameter ranges at the customer’s request.

Heat exchanger ageing tests

Ageing tests under static pressure

Technical parameters

Pressure of the working fluid in the system: 0-3 bar
Fluid in the system: OEM coolant
Fluid temperature: up to 120°C
Temperature in the chamber: up to 90°C
Number of test objects: up to 8

Sample test types carried out on systems

Ageing test in accordance with Volvo 09186804, VW TL 874

Tank high flow thermal ageing test bench

Technical parameters

Medium: various types of coolant
Temperature: up to 150°C
Total flow rate: up to 30000 l/h
Pressure: up to 2.5 bar

Chamber for temperature testing

Ageing tests (under constant and cyclic temperature conditions)

Technical parameters

Internal dimensions: 1340 × 900 × 900 mm
Chamber internal temperature: up to 140°C
Pressure within the test objects: up to 5 bar
Number of test objects: up to 4

Chamber for climatic testing

Ageing tests (under constant and cyclic temperature and humidity conditions)

Thermal shock tests (using 2 chambers)

Technical parameters

Internal dimensions: 1650 × 1050 × 950 mm
Chamber interior temperature: -40 to 180°C
Humidity: up to 98% RH
Pressure within the test object: up to 5 bar
Number of test objects: up to 4

Testing internal and external corrosion and erosion of heat exchangers

Internal corrosion/erosion

Heat exchangers are subjected to simulation of operation under specific conditions of pressure, temperature and volume flow of the cooling liquid employed (based on ethylene glycol, e.g. Havoline, G48, Paraflu, etc.) or modified liquid, accelerating the erosive or corrosive process, depending on the nature of the test type. These parameters can be fixed or variable (cyclic). The result of the simulation is a leak test or/and metallographic evaluation.

Devices

Ebara liquid pumps (range: Q = 0 to ~15 m³/h)
Grundfos liquid pumps (range: Q = 0 to ~17 m³/h)
Grundfos liquid pump, type CRN45-1 (range: Q = 0 to ~45 m³/h)
Siemens electromagnetic flow meters
ABB electromagnetic flow meters
Wika pressure transmitters (range: 0 to 4 bar rel.)
Czaki type K and T thermocouples

Testing norms

ASTM D2570

Customer norms

Ford, CEVT, Volvo, VW (LAH 03L 131), Renault, GMW, PSA, Audi, BMW, Daimler, Chrysler, Toyota, Nissan, Honda, Kia, Fiat, Jaguar, Land Rover and others.

Testing internal corrosion/erosion

Technical parameters

Coolant or corrosive H₂O carrier (according to customer specification, e.g. ASTM D2570)
Flow: up to 600 l/min
Pressure: up to 3.5 bar
Coolant temperature: up to 120°C
Number of test objects: max. 2

Metallographic examinations are performed after the test.

Explanations (of installation schematic)

Recording computer
Cubicle
Pump cubicle
Heat tank
Heater
Temperature sensor
Hot fluid pump
Double heat exchanger
Expansion tank
Flow meter
Radiators under test
Pressure sensor
Fan
Fan motor
Fan cubicle
Shield

Valve

Flow direction

Internal corrosion tests of EGR coolers and CAC coolers

Internal corrosion test at elevated temperature (with metallographic analysis following the test).

Technical parameters

Medium: exhaust gas condensate (pH 1.5-2.5) or corrosive fluid (following customer instructions).
Cycles: dry/wet.
Dry cycle temperature: up to 300°C.
Maximum number of test objects: 6.

Example test

In accordance with VW LAH 03L 131

Internal corrosion/erosion test at constant or variable pressure

Technical parameters

Test fluid: coolant or corrosive water – according to customer requirements (e.g. in accordance with ASTM D2570)
Volumetric flow rate (HT section): up to 12000 l/h
Volumetric flow rate (LT section): up to 1200 l/h
Pressure: up to 3.5 bar (absolute)
Coolant temperature: up to 120°C

Metallographic examinations are performed after the test.

Explanations (of installation layout drawing)

Heater
Heat exchanger
Hot fluid pump
Heatsink under test
Balance tank
Temperature sensor
Frequency converter
Pressure sensor
Flow meter

External corrosion

Testing the external corrosion resistance of products using a salt chamber

The chamber allows for complex tests to be carried out, using a combination of salt fog, water condensate, air, temperature and humidity.

Technical parameters

Workspace dimensions: 2865 × 1020 × 710 mm
Volume: 2500 dm³
Temperature range: 35-49°C
Humidity: 95-100% RH
Pressure of air spray: 1 bar
Pressure within test object: up to 25 bar

Some examples of the test capabilities of the chamber

VDA 233-102
DIN 50021 CASS
DIN 50021 SS
DIN 50017 KK
DIN 50017 KTW
DIN 50017 KFW
VDA 621-415
ASTM G85 A3 (SWAAT)
ASTM B117
ISO 9227
GME 60 2006
VW PV 1210
Fiat 50180*

*Customer to provide norm for testing

Freon emission tests – leak testing of automotive air conditioning systems

Leak testing in automotive air conditioning systems based on determination of the amount of refrigerant released. The test method consists of conditioning the test object in a sealed temperature chamber (MINI SHED) and analysing the concentration of refrigerant inside the MINI SHED using gas chromatography with flame ionisation detection (GC-FID).

Devices

MINI SHED chamber
- internal dimensions: 600 × 600 × 1000 mm
- temperature: up to 130°C
Agilent 7820A gas chromatograph

Thermal efficiency

Tests of thermal efficiency: coolers, intercoolers and other heat exchangers

Technical parameters

Air flowrate: 360-12 500 kg/h
Air temperature: 10-40 (50)ºC
Coolant type: H₂O, 35 and 50% glycol
Coolant flowrate: 500-17000 l/h
Coolant temperature: up to 100ºC
Coolant heater power: 130 kW
Temperature of charge air: up to 220ºC
Flowrate of charge air: 70-1500 kg/h
Pressure of charge air: 0.5-2.5 bar
Charge air heater power: 70 kW
Oil temperature: up to 145ºC
Oil flowrate: 2-40 l/min
Heater power: 15 kW

Testing fan characteristics

Technical parameters

Air flow rate: 360-12500 kg/h
Air flow resistance up to 2300 Pa
Air temperature: 10-40ºC
Supply current: up to 100 A
Rotational speed: up to 10000 rpm
Possibility of powering systems with PWM

Metallographic examination of heat exchangers

Metallographic testing of heat exchangers is performed to assess:

corrosion – after corrosion testing of heat exchangers
soldered joints present on such products.

See more on the page: Microscopy and metallography

Resistance to water

We test the water resistance of heat exchangers in various types of tests. These may include tests such as:

damp resistance tests
resistance to high-pressure washing test
testing the resistance of products to wading through water
and many others.

See more on pages:

Tests for resistance to environmental conditions – water resistance
Water splash tests – stand for testing the resistance of components to thermal shock by cold water
Chambers and other test equipment for testing resistance to dust and water (including IP testing)

Electric fan testing

Electric fans are subjected to:

functional tests and durability tests,
tests of resistance to environmental conditions,
measurements of electrical parameters and characteristics.

Electrical fan durability testing

Electric fan blade durability testing

The test consists of cyclic acceleration and braking of the fan’s electric propeller (blade). The test can be carried out at ambient or at elevated temperatures up to a maximum of 120°C.
Data on the temperature and rotational speed are acquired during the test.

Spin to Burst test

The test consists of accelerating the fan’s electric propeller (blade) until it bursts apart. The test can be carried out at ambient or elevated temperatures, up to a maximum of 120°C.

Testing norms