Innovations in vacuum aluminum brazing furnaces for contemporary EV thermal management systems

Valsecchi Giorgio - TAV VACUUM FURNACES (Italy)

For many years, vacuum aluminum brazing (VAB) has been a foundational method in producing aluminum heat exchangers for the automotive and aerospace sectors. With the expanding electric vehicle (EV) market, VAB technology is experiencing renewed attention. Effective thermal management systems in EVs (EVTMS) are essential for keeping battery and power electronics at optimal temperatures, ensuring the reliability and longevity of these critical components.

Key elements of EVTMS, such as battery cooling chillers and battery cooling plates, depend on VAB for their production. The adoption of high-strength, magnesium-based aluminum alloys from the 6000 series for critical components, along with the use of dielectric coolant fluids, necessitates the adoption of flux-free brazing techniques to prevent contamination and ensure durability.

This paper will present the design and capabilities of modern vacuum aluminum brazing furnaces for EVTMS component production, emphasizing the technical specifications required to achieve consistent, high-quality brazed joints, including temperature control and precise vacuum conditions. The discussion will cover innovations in furnace technology that cater to the stringent demands of EVTMS manufacturing. Additionally, the available solutions aimed at enhancing energy efficiency and automating the vacuum aluminum brazing process will be explored. These advancements not only contribute to reducing operational costs but also significantly increase production efficiency andthroughput.