Presently, there are four types of radiators being manufactured: Cu or brass radiator aluminium or plastic radiator ( 3 ) steel or Cu radiator and ( 4 ) aluminium radiator ( Gottlieb 1995, 335 ) . There are several procedures involved in the industry and production of auto engine radiators. These include: press-forming, opposition topographic point welding, projecting and electrostatic crop-dusting.
Forming the form of auto engine radiators requires the application of a procedure known as press-forming. The procedure is performed with the usage of a clout and a dice ( Evans & A ; Potts 2004, 44 ) . These tough tools are manufactured from die-steel which make them resistant to tonss and dependable during the pressure procedure. The radiator ‘s chief organic structure is made up of two sheet metal panels ( “ Manufacturing a Domestic Central Heating Radiator ” Cited in DeGarmo ) . These panels are connected along the surface and outer borders. During a press-forming procedure, the two panels are stamped and are held through clamping of the panel ‘s outer border ( “ Manufacturing a Domestic Central Heating Radiator ” Cited in DeGarmo ) ; this manner, the panel is formed harmonizing to the coveted form. The panels are pressed from mild steel sheet. In order to avoid differences in thickness and wrinkling, the force per unit area ring is used in the outer border. The press-forming procedure may be performed either by individual or dual action imperativenesss. For comparatively more complex constituents, the latter is instead used. A hydraulic power is frequently required to execute the procedure ; instead, nevertheless, a motor-powered fly-wheel energy can besides be used. Pressing a panel to a more three-dimentional form poses one advantage of this procedure. Such technique tends to heighten the stuff ‘s stiffness and cut down the sum of stuff needed without holding to put on the line the quality of the finished merchandise ( Evans & A ; Potts 2004, 44 ) . Another advantage of press-forming is that it enhances the ductileness of the stuff due to stretching. As the panel is stretched, the stuff is besides hardened in the procedure. The structural strength of the stuff increases as a consequence of this hardening procedure.
Figure 2: A Press/Roll-Forming Machine
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II. Resistance Spot-Welding
The squeeze-type opposition topographic point welding procedure is a type of force per unit area welding. Ninety-nine per centum of mill dyer’s rockets are resistance topographic point dyer’s rockets, which are operated under utmost force per unit area and current ( Duffy 2001, 173 ) . The procedure involves pressing two or three metal sheets between electrode tips. In the procedure, high current and low electromotive force are delivered into the stuff. Finally, the metal is heated and melted as a consequence of the metal ‘s opposition to current flow. A dyer’s rocket is formed as the molten metal is cooled. The sum of current, force per unit area and weld clip applied determines the strength of the topographic point dyer’s rocket.
Figure 3: Topographic point Welding
Furthermore, the metal beds ‘ “ fitting-up ” in the articulation besides determines the latter. Relative to other related processs, opposition topographic point welding is faster ( & lt ; one second/weld ) ( Duffy 2001, 173 ) . The procedure does non falsify metal since small heat is applied. Nevertheless, opposition topographic point welding has several disadvantages. One is that the procedure needs to entree the panel ‘s both sides being welded and may happen it comparatively hard to aline and size the tips. It is suggested non to use the procedure to welding panels with a joint thickness of & gt ; 1/5 inch or 3 millimeter ( Duffy 2001, 173 ) .
Figure 4: Aluminum welding of a auto radiator
In order to entree the panel ‘s outer border, another procedure known as “ opposition seam welding ” is extremely suggested ( “ Manufacturing a Domestic Central Heating Radiator ” Cited in DeGarmo ) – a alteration of topographic point welding. In the procedure, rollers or revolving wheels are used alternatively of electrodes. AC power with high frequence and slow crossbeam velocity is supplied through the rollers. A joint which is liquid and gas-tightened is produced from uninterrupted seam as multiple topographic point dyer’s rockets overlap.
Car engine radiators besides undergo different casting procedures. The application of heat causes metals to run and go liquid metal. Finally, the liquid metal is poured inside a cast. Depending on the metals being dramatis personae, casts may be produced from sand, ceramics or metal steel. With regard to casting, the undermentioned procedure countries should be considered: ( 1 ) flow of the liquefied metal ( to the cast ) ( 2 ) the metal ‘s chilling and hardening and ( 3 ) the type of mold stuff ( “ Metal Casting Processes ” : A Power Point Presentation ) . Engine constituents like aluminum-made radiators are manufactured through a procedure known as sand-casting. The procedure involves the readying of sand to incorporate oils. The oils help adhere and keep the form of the cast as the hot metal is being cast ( Evans & A ; Potts 2004, 47 ) . After the metal has solidified, the sand cast is broken go forthing the merchandise. The industrial die-casting procedure is another casting technique utilized in the compaction of the plumbing adjustments attached to the radiator. In the procedure, the molten metal is delivered into the die pit. The usage of four or more slides ( multi-slide die-casting procedure ) enables the procedure to bring forth complex three-dimentional molded constituents or merchandises ( Evans & A ; Potts 2004, 48 ) . Every dice constituent is secured to one slide which has either a nucleus ( internal ) or a pit ( external ) . The coveted form of the merchandise is acquired when the forms are closed together with the other dies.
Figure 5: A conventional illustration of sand projecting procedure.
IV. Electrostatic Spraying
A surface coating is required on the exterior of the completed radiator. This shall chiefly protect the constituent from corrosion. Spray painting through an industrial procedure known as electrostatic or electro-coating crop-dusting is one method that is widely favored ( “ Manufacturing a Domestic Central Heating Radiator ” Cited in DeGarmo ) . Unlike other industrial spray picture processs, the pigment atoms utilized under this method are charged “ electrostatically ” ; that is, these atoms are attracted to surfaces with a “ unvarying disciple coating ” . Under electrostatic crop-dusting, paint loss can be reduced to every bit low as 10 % comparative to other conventional spraying methods which account every bit much as 70 % of pigment loss ( “ Manufacturing a Domestic Central Heating Radiator ” Cited in DeGarmo ) .
Figure 6: Electrostatic Spray Equipment.
The “ powder-coating ” procedure is another industrial crop-dusting process utilized in the industry of auto engine radiators. In the procedure, the “ powdery ” pigment can be applied utilizing two techniques: electrostatically- charged or non-electrostatically charged. In the instance of the former, an electrostatic spray gun is used to use the pulverization into a certain portion of the constituent. The pulverization wraps the back portion as it passes into the air off return system. The pulverization is collected and filtered expeditiously and as a consequence, material use procedure is enhanced to 95 % ( “ The Powder Coating Process ” ; hypertext transfer protocol: //www.pentlandpowdercoating.co.uk ) .