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Heat exchanger testing

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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
Badania starzeniowe pod stałym ciśnieniem

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
Komora do badań temperaturowych

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
Komora do badań klimatycznych

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.

Badanie korozji i erozji wewnętrznej
Schemat instalacji

Explanations (of installation schematic)

  1. Recording computer
  2. Cubicle
  3. Pump cubicle
  4. Heat tank
  5. Heater
  6. Temperature sensor
  7. Hot fluid pump
  8. Double heat exchanger
  9. Expansion tank
  10. Flow meter
  11. Radiators under test
  12. Pressure sensor
  13. Fan
  14. Fan motor
  15. Fan cubicle
  16. 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
Przykład instalacji do badań
  • Internal corrosion test of an EGR cooler
    Internal corrosion test of an EGR cooler
  • Internal corrosion test of an EGR cooler
    Internal corrosion test of an EGR cooler

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.

Badanie korozji i erozji wewnętrznej ze stałym lub zmiennym ciśnieniem
Schemat Instalacji

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
Komora solno-cykliczna Liebisch

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
Komora Mini Shed

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
CAC on test bench

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

Metalografia wymienników ciepła

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:

  • High-pressure water resistance test
    High-pressure water resistance test
  • Surfacing the test object with a spray tube, oscillating - IPX3 IPX4 test
    Surfacing the test object with a spray tube, oscillating – IPX3 IPX4 test
  • Testing of resistance of products to wading – electric fan testing
    Testing of resistance of products to wading – electric fan testing
  • Splash test stand
    Splash test stand

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

  • ESJN11-8C607-A1 p.4.14, p.4.15
  • ESH1BG-8C607-AB p.4.14, p.4.15
  • ES 3S71-8C607 BA p.III.X

The basic parameters of the device for testing propellers (fan blades)

  • Maximum propeller diameter: 700 mm
  • Temperature: up to 120°C
  • Maximum rotational speed: 12000 rpm
  • Possibility of reaching underpressures below 50.8 mmHg (Abs)
  • Durability graph
    Durability graph
  • Spin graph
    Spin graph
  • Propeller
    Propeller

Fatigue and durability testing of heat exchangers

Heat exchanger spigot connector bending tests in a temperature chamber

Test zginania króćców wymienników ciepła

Technical parameters

  • Frequency: up to 10 Hz
  • Internal pressure: up to 3 bar (constant)
  • Bending torque: up to 20 Nm
  • Temperature range: from -30°C to +130°C
  • Load signal acquisition
  • Possibility of simultaneous load application to more than one spigot
  • Possibility of load application in three directions
  • Tensometric stress tests
Test zginania króćców wymienników ciepła

Sample specifications

  • Specification CEVT 0005952/1 p.3.4.4
  • Lastenheft 10356669-000-02, point 6.2.2.9.
  • Lastenheft 10274837 000 03, point 6.1.3.9.
  • Lastenheft 10533102-000-02, point 6.2.2.9
  • QV 17003, point. 2.2.2.4
  • Specification Volvo 09186804 p.3.4.4*

*Customer to provide norms for testing

Tests of heat exchanger components as well as complete modules

Low speed crash test for heat exchanger components and complete modules

  • Impact energy: up to around 300 J
  • Registration by means of high speed camera

Heat exchanger tightness tests

Test zginania króćców wymienników ciepła
  • Tightness test, leak source location
  • Maximum air pressure: 4.0 bar
  • Maximum nitrogen pressure: 25 bar
  • Maximum helium pressure: 40 bar
  • Accuracy of air pressure setting: ±0.1 bar
  • Accuracy of nitrogen pressure setting: ±0.1 bar
  • Temperature: ambient

Sample technical requirements

  • QS 17003 (17.05.2000), point 2.2.2.2
  • Lastenheft 10356669 000 02, point 6.1.2.1*

*Customer to provide norms for testing

Fan tests

  • Acquisition of load signal
  • Temperature: ambient
  • Following the temperature cycling test
  • Following the heat stability test
  • Following the simulated service test

Sample technical requirements

  • Fiat 9.02217, point 2.9.
  • Ford ES 3S71-8C607-BB (14/03/2005), point III. T.*

*Customer to provide norms for testing


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