1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2009 SAE International All rights reserved. No part of this publication m
3、ay be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA)
4、 Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SURFACE VEHICLE RECOMMENDED PRACTICE J1542 JUN2009 Issued 1989-01 Revised 2009-06 Superseding J1542 FEB2003 Laboratory Testing of Vehicle and Industrial Heat Exchangers for Thermal Cycle Durability RATIONALE This doc
5、ument was revised to include the use of SAE J2679, Charge Air Cooler Leakage, as a method for testing charge air coolers for integrity before and after thermal cycle testing. Other minor corrections have been made to spelling, punctuation, and formatting. 1. SCOPE This SAE Recommended Practice is ap
6、plicable to all liquid-to-air, liquid-to-liquid, air-to-liquid, and air-to-air heat exchangers used in vehicle and industrial cooling systems. This document outlines the tests to determine durability characteristics of the heat exchanger under thermal cycling. 1.1 Purpose This document is to provide
7、 a test guideline for determining the durability of a heat exchanger under thermal cycle conditions. 2. REFERENCES 2.1 Applicable Publications The following publications form a part of this specification to the extent specified herein. Unless otherwise specified, the latest issue of SAE publications
8、 shall apply. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. SAE J1597 Laboratory Testing of Vehicle and Industrial Heat Exchangers for Pressure-Cycle Du
9、rability SAE J1598 Laboratory Testing of Vehicle and Industrial Heat Exchangers for Durability Under Vibration-Induced Loading SAE J2679 Charge Air Cooler Leakage Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license f
10、rom IHS-,-,-SAE J1542 Revised JUN2009 Page 2 of 6 3. OBJECTIVE To verify compliance with established criteria that insures durability in a specific application. This document describes a system to thermally induce stresses into a heat exchanger at specified rates and temperatures. The process is acc
11、omplished by heating and cooling the heat exchangers in a specified manner. 4. FACILITY REQUIREMENT The facility should provide the following as required: 4.1 Source of “HOT” fluid capable of delivering the fluid to the test unit at specified temperature and pressure. 4.2 Source of “COLD” fluid capa
12、ble of delivering the fluid to the test unit at specified temperature and pressure. 4.3 Compressed air at specified pressure and temperature. 4.3.1 Charge air cooler test media. 4.3.2 Determination of product integrity. 4.3.3 Evacuation of steam condensate after heating cycle if required. 4.4 Means
13、of moving these fluids to and from the test unit in a specified manner. 4.5 Means of checking heat exchanger integrity. 4.6 A control system adequate to control the thermal cycle as specified. It may include the following: a. Flow measuring devices b. Pressure gauges c. Pressure switches d. Fluid fi
14、lters e. Temperature indicators f. Pressure regulators for each fluid g. Relief and back pressure regulators h. Automatic energy shut-downs i. Electrical relays, timers, switches, indicator lights, and related items as required j. Thermal cycle counters k. Safety features as specified by regulatory
15、codes and common practices l. Heaters and controls m. Automatic data logging equipment (See Figure 1 for typical control system for reference.) Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J15
16、42 Revised JUN2009 Page 3 of 6 5. TESTING 5.1 Check heat exchanger for integrity. For charge air coolers, use the methods described in SAE J2679, Charge Air Cooler Leakage, to verify that leakage does not exceed acceptable levels 5.2 Install test heat exchangers as specified (orientation and support
17、 as in service, if possible) in a safe manner. 5.3 Set up control system to obtain specified cycle (see Figure 2 for typical thermal cycle). 5.3.1 Typical Thermal Cycle Test Temperature Differential (See Table 1.) TABLE 1 - TYPICAL THERMAL CYCLE TEST TEMPERATURE DIFFERENTIAL Type of Heat Exchanger T
18、emperature Differential(1)Radiator (Liquid-to-Air) 80 C (144 F) Air Cooled Oil Cooler (Oil-to-Air) 110 C (198 F) Liquid Cooled Oil Cooler (Oil-to-Liquid) 110 C (198 F) Air Cooled Charge Air Cooler (Air-to-Air) 175 C (315 F) Liquid Cooled Charge Air Cooler (Air-to-Liquid) 140 C (252 F) 1. Differentia
19、l temperatures are typically modified and agreed to in accordance with customers reliability targets. An example is increasing the temperature differential to reduce the test duration. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permi
20、tted without license from IHS-,-,-SAE J1542 Revised JUN2009 Page 4 of 6 FIGURE 1 - TYPICAL CONTROL SYSTEM Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J1542 Revised JUN2009 Page 5 of 6 FIGURE
21、2 - TYPICAL THERMAL CYCLE 5.3.2 “Hot” Temperature is specified based on specific application. This temperature is to be at least equal to normal operating conditions. The system shall be capable of maintaining this temperature. 5.3.3 “Hot-Cold” Test temperature differential is based on individual ap
22、plication. A controlled temperature should be maintained within 6 C (11 F) by controlling either hot or cold source to take advantage of available resources. 5.3.4 “Cold” Temperature is established by test temperature differential. 5.3.5 The test cycle and its segments are to be based on specific ap
23、plication and are measured in seconds. The transition time from HOT to COLD will vary depending on test media, test equipment, and test method. One cycle consists of a heating segment and a cooling segment. A segment is that time required to bring the outlet temperature to within 5% of inlet tempera
24、ture. It is desirable to minimize segment duration in order to expedite testing and maximize thermal cycle loading. To this end, and to insure compliance with outlet temperature goals, it may be required to circulate ambient media. 5.3.6 Test ambient temperature is to be specified based on specific
25、application. 5.3.7 Nominal pressures and pressure ranges observed within the test should be recorded and maintained. 5.4 Run test to specified conditions mutually established between supplier and user or documented on part print. Types of tests are as follows: Copyright SAE International Provided by
26、 IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE J1542 Revised JUN2009 Page 6 of 6 5.4.1 New heat exchanger (no previous testing) for comparison to previously established criteria. 5.4.2 Used heat exchanger if specified (document previ
27、ous history). 5.5 Remove and check heat exchanger for leaks and structural damage. 6. TEST DOCUMENTATION 6.1 During and after test, document leakage rate and location of leaks as well as compare to acceptance criteria. 6.2 Document the following variables: a. Unit Orientation (Reference 5.2) b. Maxi
28、mum Temperature (Reference 5.3.2) c. Temperature Differential (Reference 5.3.3) d. Fluid Type 1. Hot (Reference 4.1) 2. Cold (Reference 4.2) e. Test Ambient (Reference 5.3.6) f. Unit Pressure Range (Reference 5.3.7) g. Cycle and Segment Duration (Reference 5.3.5) h. Number of Cycles to Completion (R
29、eference 5.4) 7. This document is valid for durability comparison of thermal cycle conditions only. Correlation to field results must be developed on individual basis. Other tests affecting heat exchanger durability are described in SAE J1597 (pressure cycle) and SAE J1598 (vibration). These tests c
30、an be run in combination as well as independently. NOTE: Combination testing may make it difficult to determine cause of failure. 8. NOTES 8.1 Marginal Indicia A change bar (I) located in the left margin is for the convenience of the user in locating areas where technical revisions, not editorial ch
31、anges, have been made to the previous issue of this document. An (R) symbol to the left of the document title indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in original publications, nor in documents that contain editorial changes only. PREPARED BY THE SAE COOLING COMMITTEE Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-
