Radiator manufacturing

when the gasoline and a car engine burns up to 70% of the energy generated converts into heat a lot of this heat goes out the exhaust system but much of it stays heating up the engine the cars cooling system prevents overheating the car engine. This  systems has a key component known as  the radiator .In the radiator a water and antifreeze mix absorbs the heat generated by the engine the fluid. This fluid  flows through the radiators tubes to cool down the tubes .These tubes are made from  paper  thin brass  rollers bend the four centimeter wide strip into the shape of a flat tube. This tubing system which  runs through a vat of bubbling hot molten lead . 

when this tubing exits to that it runs through cold water that hardens the lead coating. With the help of a  cutter which  chops the tubing into pieces the length of which varies according to the model of radiator. These are about 76 centimeters long mean while another machine make a narrow strip of copper just one and a half millimeters thick into what are called cooling fins. This machine folds the copper strip fan-like then perforates it creating mini air vents. when the hot fluid runs through the tubes these fins will transfer the heat to the air flowing through the radiator.

The cooling fluid can then go back for another round of absorbing engine heat the cooling fins come out of the machine  cut to size. The  workers manually stack the tubes and fins one on top of the other. They straighten them out then apply a brass tag indicating the model number and date of production. The radiator is  compressed  and strap the components together elsewhere a computer-guided machine punches out a pattern on brass sheets. These will become what are called headers. there’s one on each side of a radiator the punching tool which changes to a knife. which now cuts along the perforation lines using a press. It has been bend each header then punch slots for the radiators tube snow using a mallet.

It is  hammered the headers on to the ends of the tubes the banging inadvertently closes a few tubes .Therefor using  a special roller to reopen them after cleaning the surface sits into an oven at 315 degrees Celsius in just two minutes. The lead melts fusing the tubes and cooling fins after straightening out any crooked tubes workers dip the headers in a tank of hot liquid lead for 30 seconds. this Sauter’s them to the sides of the radiator.

To apply a few drops of lead on the corners for reinforcement the headers and tube openings are now encase in lead worker snow feed a sheet of brass into a press to form the tanks that go on to the headers one contains a brass tube hot transmission oil enters one end of it and exits the other cooling along the way. once this work has been  finish welding the tanks to the headers then they solder on what’s called the filler neck .

A spout for pouring antifreeze into the tank on the opposite tank they weld on a water intake pipe. it will be the entry point for the fluid heated by the engine finally it is  coated the finish radiator in an asphalt based black paint .The asphalt content makes the paint heat-resistant and protects the radiators cooling fins.

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