23 rd International Symposium on Transport Phenomena

Auckland, New Zealand

1922 November 2012

Effects of Brazing Layer on Strength of Inside Structure

o f a Novel Flue Gas-Water Heat Exchanger
T. Fukue1 , C. Spitas1 , M. Ishizuka2 and S. Yu 1
1
Dept. of Design Eng., Delft Univ. of Tech., Landbergstraat 15, 2628 CE Delft, the Netherlands.
2
Dept. of Mech. Syst. Eng., Toyama Prefectural Univ., 5180 Kurokawa, Imizu 939-0398, Japan.

Abstract To achieve the problem of the processing cost, we are planning

This study describes the effects of brazing layer on strength of
inside structure of a novel flue gas water heat exchanger to
maintain reliability of heat exchanger design. We especially
focus on strength of heat exchange part between the flue-gas and
the water when we construct the heat exchange part by brazing.
We investigated the strength of the heat exchange panel with the
brazing part by using 2D-FEM. We compared the results of the
2D-FEM analysis in the case without the brazing layer with those
of the case with the brazing layer. From the results, it is found
that an existence of the brazing layer decreases the strength of the
heat exchange part by stress concentration on the surface of the
brazing layer. In addition the surrounding structure around the
brazing layer also affects the ma ximum Von-Mises stress on the
brazing layer.
Nomenclature
c duct pitch [m]
d water duct diameter [m]
P water pressure [Pa]
R surface radius of brazing layer [m]
surface radius at outside corners of
r1
heat exchange panel [m]
chamfering radius at inside corner of
r2
heat exchange panel [m]
tc thickness of brazing material [m]
tp thickness of each stainless sheet [m]
clearance of brazing part [m]
to product the heat exchange part by using the following way:
Two stainless sheets with grooves are made by a press. The
pressed sheets are bonded by a brazing. By using bonded sheets,
the heat exchange part is composed. The grooves work as water
ducts and clearances between the bonded panels work as flue-gas
passages. We hereafter call the bonded heat exchange panels
simply panel .
By the use of the press and the brazing, we can product the
panel easily and cheaply. However, to use the brazing, we must
investigate the strength of the brazing. Brazing thickness is
usually enough thin. However, a brazing material is usually
different from a base material of the panel and an existence of
brazing parts may affect strength o f the heat exchanger [3]-[5]
and may cause a stress concentration [6]. To evaluate the
reliability of the proposed process, we should investigate whether
the proposed structure can sustain the designed water pressure or
not.
With this as background, we investigated the effects of the
brazing on the strength of the heat exchange panel by using 2D-
FEM (Finite Element Method). Moreover we investigated the
effects of a base panel thickness, a duct pitch, a brazed area, a
surrounding structure around the brazing part on the stress
concentration on the brazing layer.

Introduction
Recently a demand of an exhaust heat exchanger which collects
heat from thermal equipment s flue gas is developing to improve
thermal efficiency of thermal equipment and save energy [1]. To
incorporate an exhaust heat exchanger into thermal equipment at
low cost, a new concept heat exchanger, which has high heat
exchange performance while keeping down a production cost, is Figure 1. Whole Design of UCCHE-A.
urgently demanded.
We are now designing a novel ultra compact flue-gas/water
heat exchanger: UCCHE-A (Ultra-Compact Condensing Heat
Exchanger) [2]. Figure 1 shows the whole image of the heat
exchanger. It is designed for use with boilers firing natural gas or
other sulphur-free fuel. We are planning to develop the heat
exchanger with a lightweight compact stainless-steel structure
which can sustain 10 bar of water pressure.
The heat exchanger is mainly composed of an enclosure and a
heat exchange part as shown in Figure 2. To develop the heat
exchanger without compromising versatility, we must choose a
cheaper and high-reliability processing method. Especially, to
sustain high water pressure while decreasing a production cost,
we must optimise the processing method of the heat exchange
part. Figure 2. Inside Structure of UCCHE-A.
Analytical Model and Condition panel shape around the brazing layer on the strength. We
investigated whether the panel shape can be changed easily while
Figure 3 shows 2D analytical models for an investigation of the
maintaining the strength of the heat exchange part or not by using
strength of the panel. To investigate the stress distribution this model. The shape of the corner inside the panel has the
between two water ducts, we prepared the analytical model notable effect on the stress of the brazing layer. We investigated
around two water ducts. We hereafter call each analytical model
the strength while changing the chamfering radius inside the
simply model 1 Model 2 Model 3 and Model 4 as shown
panel r 2 and the brazing clearance as shown in Fig. 4 (d).
in Fig. 3.
Through the analysis, we investigated the effect of the panel
Model 1 is the standard of the analytical model in this report.
structure on the strength of the brazing layer. Here, in Model 4, r 1
In this model, we assumed that two panels are bonded directly.
value became same as r 2 to prepare the analytical model easily.
Hence this does not include the brazing layer. Here, surface
Here, we assumed that the brazing layer and each stainless sheet
radius at outside corners of the panel r 1 is formed to avoid the
were completely bonded. Actually there may cause some defects.
occurrence of a stress concentration outside the panel. Model 2 is
However at present we cannot discuss the effects of these defects
the analytical model with the brazing layer. The brazing layer is
easily. Therefore in this study we targeted to clarify the effects of
located between the pressed panels. The difference between
the brazing from the viewpoint of the change of the structure and
model 1 and 2 is whether there is the brazing layer or not. By
the shape which may cause stress concentration.
comparing results of model 1 and 2, we investigated the effects
Table 1 shows mechanical properties. The material of the sheet
of the brazing layer on the stress.
was assumed AISI318 and the brazing material was assumed
In addition, to investigate the effects of conditions around the
pure copper.
brazing layer, we prepared additional two models, which are
We used Solidworks Simulation as the 2D-FEM code. Figure 4
model 3 and 4. Model 3 is the model to investigate the effects of
shows the boundary condition of the analysis. Point <A> as
the brazing condition on the strength. We calculated the strength
shown in Figure 5 was fixed. Surface <B> and <C> were set to
while changing the length of the clearance ( ) and investigated moving wall. We applied 1 MPa of the normal stress on the inner
the relationship between the size of the clearance and the stress
surface of the water ducts. This simulated the water pressure.
concentration. Model 4 is the model to observe the effects of the tp

tb
tp

c/2 c c/2

c/2 c c/2
Duct cross section : Circular
Duct diameterd : 8 mm
Duct cross section : Circular Duct pitchc : 2d ~ 3.5d
Duct diameterd : 8 mm Panel thicknesst p : 0.5 mm, 1mm
Duct pitchc : 2d ~ 3.5d Paneloutside cornerr1 : 1 mm
Panel thicknesst p : 0.5 mm, 1mm Brazingthicknesstb : 50 m
Panel outside cornerr1 : 1 mm Panel material: : AISI318
Panel material: : AISI318 Brazing material : Copper
( a ) M o d el 1 (b) Model 2
tp
tb
tp

tb

c/2 c c/2
c/2 c c/2
Duct cross section : Circular
Duct cross section : Circular Duct diameterd : 8 mm
Duct diameterd : 8 mm Duct pitchc : 2d
Duct pitchc : 2d ~ 3d Panel thicknesst p : 0.5 mm
Panel thicknesst p : 0.5 mm Panel outside cornerr1 : 0.5mm~2 mm
Panel outside cornerr1 : 1 mm Panel inside cornerr 2 = r1
Brazingthicknesstb : 50 m Brazingthicknesstb : 50 m
Clearance : 0 ~ 1000m Clearance : 0 ~ 1000m
Panel material: : AISI318 Panel material: : AISI318
Brazing material : Copper Brazing material : Copper
(c) Model 3 (d) Model 4

Figure 3. Analytical models of heat exchange panel.

Here, because of the restriction of the software, the pressure is Effect of Duct Pitch
applied only on the inside surface of the water duct wall
Figure 7 and 8 shows the effect of water duct pitch on the
regardless of the existence of the blazing layer, the clearance and
the shapes of the panel. To maintain analytical accuracy while a ma ximum Von Mises stress. Figure 8 is the result in the case of t p
calculation cost decreases, we defined the maximum mesh size of = 0.5 mm. Figure 8 is the result in the case of t p = 1.0 mm. The
ma ximum Von Mises stress is not changed when the duct pitch is
the analytical model was set as follows; the maxi mu m mesh size
changed. We can say that the duct pitch has no effect on the
of the stainless sheet was set 50 m and the brazing layer was set
strength of the panel. Therefore we can optimize the duct pitch to
4.5 m.
perform the highest heat exchange performance without
consideration of the strength.
Analytical Results
Effect of Brazing Layer
First of all, we investigate the effect of the brazing layer on the
strength. Figure 5 shows the result of maximum Von Mises stress
in the case of model 1 and model 2 when c = 2.0d. We can see
30
that maximum Von Mises stress become higher regardless of the tp = 0.5mm

Maximum Von Mises stress

thickness of the stainless sheet when there is the brazing layer. 25 tp = 1.0mm
When there is the brazing layer, the maximum Von Mises stress
is increased by two times that of the result without the brazing 20
layer. Then, when the thickness of the panel is thicker, a value of
the maximum Von Mises stress decreases regardless of the

[MPa]
existence of the brazing layer. By using the thicker stainless sheet, 15
we may decrease the Von Mises stress of the brazing layer.
Figure 6 shows the distribution of Von Mises stress in the 10
case of model 1 and model 2 when c = 2.0 d and t p = 0.5 mm.
Regardless of the existence of the brazing layer, the Maximum
Von Mises stress is caused on the bonded point of the water duct
5
side. When there is the brazing layer, the maximum Von Mises
stress is caused on the surface of the brazing layer. From this 0
result, we can say that the existence of the brazing layer causes Model 1 (W/O Model 2 (With
the stress concentration on the surface of the brazing layer and
the value of maximum Von Mises stress increased. Filler) Filler)

Figure 5. Effect of brazing layer on maximum Von Mises Stress.

Values
Parameters
Base Sheet Brazing

Material AISI318 Copper a)

Von Mises
Density [kg/m3] 7800 8900 [MPa]
11.1

Youngs modulus [MPa] 19.5 10 4 11 10 4

y
Poisson ratio 0.30 0.37 x 0.0

Shear modules elasticity [MPa] 7.5 10 4 4 10 4

UTI [MPa] 620 395 b)

Von Mises
Yield stress [MPa]
450 259
/ 0.2 % proof stress [MPa] 25.5

Table 1. Material Properties of the panel and the brazing filler.

y
x 0.0

<A>

p p
Stress concentration

<B>
<C>
p: pressure boundary (10 bar = 1MPa)
:fixed :moving
* Simulate water pressure. Figure 6. Distribution of Von Mises stress in the case of c = 2.0 d
and t p = 0.5 mm : a) without brazing layer (model 1), b) with
Figure 4. Boundary conditions of analytical model. brazing layer (model 2).
 40 250
Model 1 : W/O Filler

Maximum Von Mises Stress

Maximum Von Mises Stress

35
Model 2 : With Filler 200
30
25 150

[MPa]
[MPa]

20
15 100
c = 2.0d
10
50 c = 2.5d
5 c = 3.0d
0 0
2.0 c 2.5c 3.0 c 3.5c 0 500 1000 1500
Water Duct Pitch [mm] [m]
Figure 7. Effect of water duct pitch on maximum Von Mises Figure 9. Relationship between and maximum Von Mises stress
Stress in the case of t p = 0.5 mm. in the case of Model 3.

700
40
Maximum Von Mises Stress

Model 1 : W/O Filler 600

Maximum Von Mises Stress

35
Model 2 : With Filler 500
30 UTI
400
[MPa]

25
[MPa]

20 300
15 200 0.2%
10 100 proof
stress
5 0
0 0 500 1000 1500
2.0 c 2.5c 3.0 c 3.5c [m]
Water Duct Pitch [mm] 1000 rr2 = 0.5mm r2r = 1.0mm
r2r = 0mm
0
m
Max
imu

Figure 8. Effect of water duct pitch on maximum Von Mises
Stress in the case of t p = 1.0 mm.
Effect of Clearance Size of Brazing Layer
We investigate the effects of the clearance size of the blazing
layer on the strength of the panel structure by using Model 3.
Figure 9 shows the relationship between the clearance size and
the maximum Von Mises stress in the case of Model 3. When the
size of the clearance increases, the ma ximum Von Mises stress
increases linearly. Here, from the result of Fig. 9, we can see that
the effect of duct pitch is little when the clearance of the blazing
layer becomes larger. Therefore it is found that the duct pitch has
no effect on the strength of the heat exchange panel regardless of
the condition of the brazing. Moreover, when the clearance size
is 1 mm, which corresponds to 20 times of the height of the
brazing layer, the Maximum Von Mises Stress is smaller than the
0.2 % proof stress of the copper.
r2r = 1.5mm
0 rr2500
= 2.0mm 1000 1500
[m]
Figure 10. Effect of corner shape inside the panel on maximum
Von Mises stress in the case of Model 4.
Therefore we can say that the strength of brazing layer may
be enough for the proposed heat exchanger when there is no
serious clearance ( > 1 mm) in the case of Model 3.
Effect of Shapes of Panel
Finally, we investigate the effects of the panel shape on the
strength of the panel structure. Especially we focus on the
influence of the inside shape of the water duct.
Figure 10 shows the relationship between the corner shape
inside the panel and the maximum Von Mises stress in the case
of Model 4. From Fig. 10, we can say that the maximum Von
Mises stress increases linearly when the size of the clearance
increases. This is the same tendency when there is no chamfering [4] Saito, S., Kayamoto, T. and Onzawa, T., Mechanical
as shown in Fig. 9 (Model 3). However, the value of the Properties of Stainless Steel Joint Brazed with Ni-Cu Based
ma ximum Von Mises stress increases when the chamfering Filler Metals (in Japanese), Transactions of the Japan
radius becomes larger. From this result, we can say that the best Welding Society, Vol. 17 No.1, 1999, pp. 35-40.
shape of the water duct to avoid the stress concentration at the
[5] Saito, S. And Onzawa, T., High Temperature Tensile
brazing layer is circular. To avoid the destruction of the heat
Strength of Stainless Steel Joint Brazed with Ni-Cu Based
exchanger from the brazing layer, we should design the panel
shape so that the shape of the cross section of the water duct can Filler Metals (in Japanese), Transactions of the Japan
become circular. Moreover, we should optimise other parameters Welding Society, Vol. 19 No.4, 2001, pp. 688-692.
such as thickness of the panel so that the heat exchange part has [6] Beer, F. P., Johnston, E. R. and DeWolf, J. T., Mechanics of
enough strength to sustain the proposed water pressure. On the Materials Fourth Edition in SI Units, McGraw-Hill, 2005.
other hand, the duct pitch can set the best value which can
perform the highest heat exchange performance because the duct [7] The Japan Society of Mechanical Engineers, JSME Data
pitch has almost no effect on the strength of the brazing layer. Book : Hydraulic Losses in Pipes and Ducts (in Japanese),
Maruzen, 2001.
Summary [8] Kowalski, T. and Radmehr, A., Thermal Analysis of an
Electronic Enclosure: Coupling Flow Network Modelling
In the present report, we analytically investigated the effects of (FNM) and Computational Fluid Dynamics (CFD), Sixteenth
brazing layer on strength of inside structure of a novel flue gas Annual IEEE Semiconductor Thermal Measurement and
water heat exchanger to maintain reliability of heat exchanger. Management Symposium, 2000, pp. 60-67.
We investigated using 2D-FEM analysis. Especially we
discussed the strength of the heat exchange part between the flue- [9] Fukue, T., Ishizuka, M., Nakagawa, S., Hatakeyama, T. and
gas and the water, which sustains high water pressure. The Nakayama, W., Resistance Network Analysis of Airflow and
following information was obtained analytically. Heat Transfer in a Thin Electronic Equipment Enclosure
The existence of the brazing layer decreases the strength of with a Localized Finned Heat Sink, The 14 th International
the heat exchange part. On the other hand, the duct pitch has no Heat Transfer Conference; IHTC-14 th, 2010.
effect on the strength of the heat exchange panel. The shape of
the water duct has notable effect on the stress concentration at the
brazing layer. To avoid the destruction of the heat exchanger
from the brazing layer, we should design the panel shape so that
the shape of the cross section of the water duct can become
circular.
The present structure of the heat exchange panel has enough
strength to stand up to 10 bar of the water pressure when the
shape of the water duct is circular and the length of the clearance
of the brazing layer is less than 1 mm. However, when there are
some defects between the heat exchange sheet and the brazing
layer, the strength may decrease. Our next study will discuss the
effects of the conditions of the brazing layer on the strength of
the panel. Of course we must investigate the optimization method
of the heat transfer performance of the heat exchanger. Moreover,
the actual heat exchanger has very complex flow pass as shown
in Fig. 1 and 2. Then flow phenomena of the preheat water may
also be complex. To discuss the effect of the preheat water
pressure on the strength of the heat exchanger accurately, we
have to investigate the details of flow phenomena and pressure
drop characteristics [7] in the water pass. On the other hand, we
would like to develop the rapid and accurate design scheme of
the heat exchanger based on the flow and thermal resistance
network analysis [8] [9] to shorten the production period of the
heat exchanger.

References
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Heat Exchanger using an Element Method with Localised
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