Our Technologies

With insights into factors such as fluid velocities, temperature distributions, and pressure gradients, we can identify potential areas of concern or areas for improvement. Our engineers evaluate various design parameters, such as fin geometry, tube layouts, and flow distribution, to achieve the desired heat transfer efficiency. CFD simulations can predict the effects of different operating conditions, fluid properties, and geometrical modifications, enabling engineers to make informed decisions regarding heat exchanger performance.

Additionally, CFD technology aids in understanding issues related to fouling. By simulating flow patterns and heat transfer characteristics, CFD helps identify regions prone to fouling and evaluate the impact of fouling on overall heat exchanger performance. This information guides the development of effective cleaning and maintenance strategies to maximize heat exchanger efficiency and minimize downtime. CFD analysis also plays a vital role in the development of our heat exchanger designs. It enables the exploration of new concepts by providing insights into their fluid flow behavior and heat transfer capabilities. With the in-house CFD technology offering a comprehensive and detailed analysis, our team can support design optimization and performance evaluation. With valuable insights into fluid flow behavior, heat transfer characteristics, and pressure distribution, we are able to develop more efficient and reliable heat exchanger systems.

Apart from multiple production techniques, our tube manufacturing technology also includes a selection of materials. Common materials used in our heat exchanger tubes include stainless steel, copper. The choice of material depends on factors such as operating conditions, corrosion resistance requirements, thermal conductivity, and cost considerations. Additionally, tube manufacturing process includes quality control to ensure the tubes meet the required standards for dimensional accuracy, mechanical properties, and surface quality. Our tube manufacturing technology ensures the efficiency and durability of our heat exchangers.

This process is particularly suitable for manufacturing heat exchanger fins, which require precise dimensions, uniformity, and smooth surfaces. Roll forming allows for high-volume production and can deliver consistent fin shapes and spacing. Another steel-forming technique is tube bending. To ensure repeatability and geometric precision of the bent element, regardless of the shape and cross-section, we use a fully electric mandrel bender with CNC control and a BLM E-TURN 52 bending machine. This technique delivers U-bends and other curved forms in heat exchanger tubes. Tube bending methods at AHE include rotary draw bending, mandrel bending, or induction bending, depending on the desired specifications and the diameter of the tubes. Steel forming technology also incorporates surface treatment processes to enhance the performance and longevity of heat exchanger components. Surface treatments such as coating, plating, or passivation improve corrosion resistance, increase heat transfer efficiency, and provide specific properties like anti-fouling or anti-adhesive characteristics.

The advantage of laser beam welding is that it allows for welding components with complex geometries or in hard-to-reach locations, as the laser beam can be directed at the joint from any angle. Mirror welding is the type of laser welding frequently used at AHE. By reflecting the laser beam off a mirror, it can be focused to a very narrow surface, producing a precise weld. In addition, the use of mirrors increases the speed of the welding process (using mirrors allows us to move from welding one joint to another without moving the laser head, which is always time-consuming). It results in an exact and accurate welding process.

The vacuum brazing technology is used for the most labor-intensive process in heat exchanger production, which is connecting the tubes to the tube sheet. When designing the brazing process for a particular product, we choose different filler materials. The elements being connected are then placed into a vacuum furnace and heated to the melting point of the brazing alloy. In the cooling process, shielding gases such as argon or nitrogen are used to prevent contamination of the joints. The vacuum brazing process allows multiple pre-prepared subassemblies to be placed in the furnace and a large number of closely spaced joints to be made simultaneously, making this method faster than laser welding in some cases.

In-house designed flat plates with properly etched microchannels are stocked in layers, one on top of the other, forming the core of the device. The stack is inserted into a diffusion bonding furnace, where, in a controlled atmosphere, it is heated up (below the melting point of the material) and evenly loaded with uniaxial pressure. The key features of diffusion-bonded heat exchangers, such as their durability, compactness, and effectiveness, make them an excellent solution for applications demanding reliability under extreme working conditions, including high pressure, elevated temperatures, and temperature differences.