Radiator Construction - Cool Stuff

Tag : Tube Sealing

No one can deny the importance of cooling systems for race cars. Inthe sometimes-superhot environs of the racetrack, a radiatorbecomes especially vital in keeping an engine cool enough to makeit to the finish line.
A radiator is one of those things that tends to be taken forgranted until it fails. Fortunately for today's racer, thereliability of radiators has been elevated to a very satisfactorylevel. Not only that, but they can also be purchased with numerousoptions, such as internal oil coolers, several rows of coolingcapacity, and any outlet configuration a racer wants.
There was a time when the only real choice in a radiator wasbetween a heavy or an even heavier unit. In the early days ofracing, radiators were cumbersome copper/brass contraptions thatoften could not stand up to the rigors of racing, and many a racerfound his fortune going up in steam as the car sputtered to a halt.
Luckily, as technology moved forward, these old-style radiatorshave become relics and have been replaced by units manufacturedfrom aluminum. Although there are some exceptions, aluminumradiators are virtually all you will find in race cars today. Andthere is a good reason for that-they're light, efficient, durable,and affordable.
Because these units are in such widespread use, Circle Trackthought this would be a good time to take a look at how today'sradiators are manufactured. To accomplish this, we spoke with BuddyGriffin of Griffin Radiator in Piedmont, South Carolina; GaryJohnson of Fluidyne Racing Products in Ontario, California, andChris Paulsen of C & R Radiator in Indianapolis. Each companycontributed information that helped us compile this simple overviewof how radiators are made.
Cool ScienceHow a radiator cools is an uncomplicated process. Insimple terms, radiator tubes provide the primary source for heatrelease. The tubes, in combination with the so-called radiatorfins, provide a broad surface area for rapid heat dissipation. Airmovement through the radiator is the final ingredient in theprocess. As air moves across and through the fins and tubes, heatis carried away, and if everything is working properly, the watertemperature is maintained at a satisfactory operational level.
Pieces To The PuzzleRadiators have several parts that go togetherin making each unit. Tubes, fins, headers, and tanks are the basicparts of a radiator, and each part has a critical function. Theradiator tubes are flat, which creates a broad surface area forheat dissipation. The fins are light aluminum ribbons, which are ina corrugated-looking configuration. The headers serve as an anchorfor the tubes and provide a link between the tubes and the watertanks. Finally, there are the water tanks, which are made to holdproper amounts of water to keep motors cool.
Putting It TogetherThe assembly of a radiator begins with theassembly of tubes and fins. This process is known as core stacking.As each core is completed, the tubes and fins are strappedtogether, then it's on to the next step: the placement of theheaders.
It's A Bonding ThingOnce the cores have been assembled, they areready for the bonding process called brazing. In simple terms,brazing is a process that takes place in a furnace for a specifiedtemperature and time. The result of this procedure is a core thatis bonded together as a strong single unit.
When the cores are complete, water tanks are mounted. The basicwater tank is designed to hold the correct volume of water to coolan engine, however, virtually any custom design can be provided.Tanks may be configured to contain oil coolers, transmissioncoolers, and baffles. Baffles are used to produce a double-passunit in which water passes through the core twice before returningto the engine.
Cool PowerThe size of a radiator, both numbers of rows, anddimensions are dependent on a given application. Racing radiatorsare available in standard and nonstandard versions, but whateverthe application, there are many quality radiator suppliersavailable to racers.
It's Tubular, ManThe very foundation of the radiator is the tubes,which are the heart of the radiator core. Tubes are formed on amachine called a tube mill, and Circle Track had the opportunity tosee one such machine at Griffin Radiator, where they make the tubesfor all of their units. Company President Buddy Griffin explainedto us how a tube mill actually works.
A tube mill is a complex series of processing units put together sothat a flat piece of aluminum ribbon is fed into one end of themachine and a finished tube is expelled out the other. In between,of course, there is a lot of high-tech stuff going on that makes itall happen.
Radiator tubes begin life as a flat piece of aluminum on a roll.The width of the aluminum will determine the size of the tube.Tubes are available in 1- 111/44-, and 111/42-inch sizes.
As the aluminum is fed into the machine, it passes through a seriesof special mill heads that channel, bend, and form the aluminuminto what becomes a tube. After the aluminum has been formed into atube shape, it passes through a final unit that welds the aluminum,thus sealing the tube.
During the process of tube making, random samples are put throughrigorous pressure and integrity checks. Each tube run is tested forpressure. Additionally, tube samples are inspected undermicroscopic conditions to verify the integrity of the weld. In theend, this quality certification ensures that the tubing willwithstand the demands of racing.
ManufacturersAFCO Racing ProductsDept CT01977 Hyrock BlvdBoonville,IN 47601812/897-0900
C & R Racing IncDept CT01286-A Gasoline AlleyIndianapolis, IN46222317/241-0774
Fluidyne Racing ProductsDept CT014850 Airport RdOntario, CA91761800/266-5645
Griffin RadiatorsDept CT01100 Hurricane Creek RdPiedmont, SC29673864/845-5000
Howe Racing Enterprises IncDept CT013195 W. Lyle RdBeaverton, MI48612516/435-7080
Ron Davis Racing ProductsDept CT017334 N. 108th AveGlendale, AZ85307800/842-5166