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Comprehensive Aluminum Vacuum Brazement Services – Design to Manufacturing

Cold Plates, Heat Exchangers, and Assemblies

Aavid Thermacore offers the complete range of design and manufacturing services for aluminum vacuum brazed cold plates, heat exchangers, and chassis' s. Aavid Thermacore's aluminum vacuum brazed products can be found in a variety of applications in the Military/Aerospace, Medical, Power Electronics, and Communication markets. We differentiate ourselves with a full service business model that includes concept generation, engineering design and development, qualification, and volume manufacturing.

Aluminum Vacuum Brazing CapabilitiesOur specialized expertise and aluminum brazing technology allows a wider variety of alloys and structural developments for stronger, more rugged and higher capacity material and thermal solutions. Aavid Thermacore's capabilities meet industry standards (AWS C3.3, AWS C3.7, AMS 2770, etc.) used in Aerospace/Defense, Medical, Semiconductor, and Commercial markets. These integrated capabilities include: 

 

  • Vacuum Brazement Concept Generation, Engineering Design & Development, Prototyping, Qualification Testing, and Volume Manufacturing
  • Precision aluminum vacuum brazing at 650°C (1200°F) under low 10-5 Torr vacuum for braze joints free of brazing salts and fluxes and free of voids.
  • Pre- and Post brazement precision machining
  • Surface preparation and cleaning
  • Complex joint design and assembly, featuring techniques that apply pressure evenly for a superior joint and enhanced mechanical and thermal characteristics
  • Heat treating, quenching and straightening of brazed assemblies
  • Acceptance testing, including 30-100 psi pressurized inert gas bubble testing, pressure decay leak testing,  and helium leak testing (pressurized sniffing or vacuum sniffing)
  • Inspection includes CMM and Optical Comparator measurement

Engineering Services

For aluminum vacuum brazed cold plate, heat exchanger, assemblies/structure design, development and manufacturing, Aavid Thermacore, offers turn-key engineered solutions. Aavid Thermacore's engineers work closely with our customer's engineers to generate solution concepts and then utilize the latest 3D solid modeling software (such as SolidWorks) and CFD analysis tools (such as Flotherm®, Star-CCM®, COSMOS/M®, ANSYS®, or ICEPak®) design the best performing thermal solution at the lowest economical cost. Aavid Thermacore's engineers are experienced with complex braze joint design, high fin density selection and sizing, design for manufacturability, and final assembly integration. At the completion of the design stage, Aavid Thermacore typically will produce a prototype for performance validation and qualification.
Our aluminum brazing process is thorough, demonstrates superb attention to detail, and yet is also rapid and flexible enough to meet any need.

Qualified to Industry Standards

Qualified by customer in the Military/Aerospace industry, Aavid Thermacore understands to important of process control and verification. Aavid Themacore's aluminum vacuum brazing services are conducted to meet the following industry standards:

  • AWS C3.3 Recommended Practices for the Design, Manufacturer, and Examination of Critical Brazed Components
  • AWS C3.7:2005 Specification for Aluminum Brazing
  • AWS B2.2:2010 Specification for Procedure and Performance Qualification
  • AMS 2678:2006 Furnace Brazing of Part in a Vacuum Atmosphere
  • AMS 2750D:2005 Pyrometry
  • AMS 2770H:2006 Heat Treatment of Wrought Aluminum Parts
  • MIL-H-6088G, Notice 1:1997 Heat Treatment of Aluminum Alloys
  • MIL-B-7883C, Notice 1:1996 Brazing of Steels, Copper, Copper Alloys, Nickel Alloys. Aluminum and Aluminum Alloys

Aluminum Vacuum Brazing Services and Capabilities

We offer precisely controlled high-temperature production brazing through our PV/T and Abar-Ipsen aluminum vacuum brazing furnaces, featuring furnace wall pre-heating and sophisticated computer control of the braze cycle. Our 150kW PVT VAB furnace is capable of a 10-5 Torr vacuum, with a hot zone 24" wide by 36" high by 48" deep. The PVT programmable control system uses 7 trim  zones to evenly deliver temperatures up to 650°C (1200°F). Our 900kW Abar-Ipsen vacuum furnace is capable of a 10-5 Torr vacuum, and includes a very large hot zone of 37" wide x 65" high x 144" (12 feet!) deep. The Abar-Ipsen programmable control system uses 20 programmable trim zones to evenly deliver temperatures up to 650°C (1200°F)  ± 2.8°C (± 5°F) temperature uniformity. Both furnaces are ideal for precision brazing. The Abar-Ipsen will be available in 2014.

Our complete range of brazing services and capabilities includes:

Services

  • Aavid Thermacore offers Aluminum Vacuum Brazement Engineering Design including Concept Creation, Design and Analysis, Development, Qualification, and Volume Manufacturing. Aavid Thermacore has been a recognized leader in thermal management technology and engineering design since 1970. Our engineers have the experience (>1000 man-hours) to offer the best combination of thermal performance, cost, and quality.
  • Toll Brazing - bring Aavid Thermacore a completed machined braze blank and we will assemble, fixture, and vacuum braze to AWS C3.7 standards, and heat treat (T-4 heat treat & T-6) on an á la carte basis with reasonable turnaround times (less than 10 working days).


Process and Capabilities

  • Raw Material Certification
    • As required, we provide raw material certifications; traceability for specific lots
  • Pre-Braze Machining
    • Aavid Thermacore offers our customers pre-braze component and post Brazement machining on 3, 4, and 5 axis precision machining centers
  • Cleaning
    • Surface cleaning and preparation, to ensure a clean, residue-free brazing surface. Aavid Thermacore employs a 6 step cleaning process that includes an alkaline ultrasonic cleaner, water rinse, vapor degreasing, and acid etch.
  • Vacuum Brazing
    • Aavid Thermacore offers precise temperature and vacuum control during the aluminum brazing process to ensure braze joint integrity meeting AWS C3.7 (or MIL-B-7883) Class A or Class B standards. Aavid Thermacore maintains vacuum levels as low as 10-6 Torr for an environment free of any oxides or impurities, and electronically monitors and records temperatures and pressures throughout the brazing cycle to provide the necessary process control  
    • Brazing furnaces include:
      • (1) PV/T with a 24" wide by 36" high by 48" deep hot zone / work zone
      • (1) ABAR aluminum vacuum brazing furnace with a very large 37" wide x 65" high x 144" (12 feet!) deep hot zone / work zone
  • Heat Treating
    • Solution heat treating using even delivery of temperatures up to 540°C (1000+°F)  is conducted an 6 foot (72")w x 6 foot (72")h x 6 foot (71")d Blue M , allow volume heat treating in support of our brazing operation. Solutuon heat treat quenching is done in both tanks and fan drive sprays. These are ovens are calibrated monthly and surveyed quarterly to comply with the requirements of AMS 2770 and MIL H 6088.
  • Aging
    • Aging is done in a Greunberg oven capable of 230°C (450°F).  These are ovens are calibrated monthly and surveyed quarterly to comply with the requirements of AMS 2770 and MIL H 6088.
  • Post-Braze Machining
    • Aavid Thermacore offers our customers post brazement assembly machining on 3, 4, and 5 axis precision machining centers.
  • Outside Processing for Surface Finishing
    • Aavid Thermacore is experienced with Chromating, Anodizing, precious metal plating (nickel, tin, gold, etc.), and painting. We have strong supplier-partnerships with NADCAP approved sources for these surface finish application requirements.
  • Mechanical Assembly
    • Aavid Thermacore offer mechanical assembly including installation of helicoils, inserts, pins, thermal interface materials, and other mechanical components.
    • Assembly of vacuum brazed products from rough machined parts, using proprietary fixtures and tooling to create superior joints and excellent heating characteristics
  • Acceptance Testing and Thermal Validation Testing Inspection
    • Acceptance Testing options include visual, bubble leak testing (using pressurized Dry N2 or other inert gas typically to 30-100 psi), and helium leak testing (vacuum or pressurized sniffing) to ensure braze joint integrity and quality. If ultrasonic testing is a requirement or desired, Aavid Thermacore utilizes a local supplier-partner for inspection.
    • Thermal validation testing under simulated applications conditions.
  • Inspection
    • Mechanical Inspection is conducted using Mitutoyo CMMs calibrated to 100 millionths of an inch precision and S-T Industries Optical comparators
      Skilled Technicians with expertise in Geometric Dimensioning and Tolerancing (GD&T)
    • Certified AWS Radiographic Interpreters.
    • Support of Customer and Government Source Inspections
  • Final Inspection and Test Data Reporting
    • Aavid Thermacore routinely provide final inspection reports and final assembly validation test reporting to our customers.
    • Certificates of Conformance
  • Packaging and Shipment
    • Aavid Thermacore will package and bar-code label our products as specified to ensure delivery is made without damage and ease of receipt at its final destination.

 

Thermal or Materials management challenge? Take the first step towards the solution for you. Contact an Aavid Thermacore technical representative.

 
Since 1970  •  AS 9100  •  ISO 9001 Certified  •  DDTC/ITAR Registered • AAVID Corporate
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