Why Choose an Aluminum Radiator?
Aluminum is one of the most common materials in vehicle and machine radiators today. In this article you will find, in measured terms, the advantages aluminum offers for radiators, the limits to be aware of, and the general difference from copper-brass radiators.
The advantages of aluminum
- Heat conductivity: Aluminum conducts heat well. Combined with thin fins, it can transfer heat from the hot fluid to the air side effectively.
- Light weight: Its density is noticeably lower than copper and brass. A radiator of the same size is lighter, which makes mounting and transport easier on mobile machines and on equipment that moves.
- Corrosion resistance: A natural oxide layer forms on the aluminum surface. Under the right conditions, this layer helps protect the metal in humid environments.
- Workability: Aluminum can be made into profiles, sheets and fins. This makes it possible to build radiators in different sizes and internal structures.
Together, these properties give aluminum a wide range of uses in the automotive sector as well as in construction machinery, compressor and hydraulic applications. It offers a reasonable balance especially where weight matters but adequate heat rejection is also expected.
Still, a material's advantage has to be read together with its operating conditions. The same aluminum radiator can serve trouble-free for a long time in a system running with clean, correct fluid, yet may not deliver the expected performance under poor maintenance and unsuitable conditions.
To be honest: the limits
No material is the best in every condition. With aluminum radiators, the following need attention.
- Coolant and water quality: Unsuitable additives or dirty, aggressive fluids can accelerate corrosion in aluminum. Use the fluid recommended by the manufacturer and the machine builder.
- Contact with dissimilar metals: If aluminum touches a different metal in the presence of an electrolyte, there is a risk of galvanic corrosion. Fasteners and line materials should be evaluated from this angle.
- Mechanical strength: In impact, vibration and dirty operating environments, the fins bend easily. Protective mounting and regular cleaning are important.
- Repair: Joining aluminum requires different processes from the soldering methods customary with copper and brass radiators. For this reason, replacement is often considered for a faulty unit.
General comparison with copper and brass
Copper is known for its high heat conductivity, and copper and brass for being repairable by soldering. Aluminum stands out for its light weight and ease of processing. Which one is suitable varies with conditions such as weight, working pressure, environment, fluid and budget. So the question to ask is "which material suits the application", not "which is the best material".
In practical terms: if light weight, reasonable heat conduction and ease of processing are priorities, aluminum is a strong candidate. If repairability or compatibility with a specific fluid is the priority, other materials are also considered. It is best to make the decision based on the data from the manufacturer of the machine and of the fluid.
On mobile machines, weight affects fuel consumption, mounting load and the support connections, so a lighter housing is an extra advantage. In fixed installations weight matters less, and the decision mostly comes down to pressure, fluid and maintenance conditions.
A bridge to bar-plate construction
The advantages of aluminum make sense when combined with the internal construction. In the aluminum bar-plate construction used in Safkan oil radiators, the separator design placed in the oil channels creates turbulence in the flow and improves heat transfer. This construction is preferred in oil coolers designed to withstand high pressure.
You can see the products that use this construction on the compressor radiators and fan-cooled radiators pages. If you are curious about the basics of oil cooling, the article what is oil cooling is a good place to start.
If you would like technical information on material and model selection for your application, you can reach us through our contact page.