Quality Control Hairpin Leak & Damage @ Expander & Brazing Station

Date: 16-Nov-09 Problem: Leaks and hairpin free-length damage & deformation are reported from the field as well as seen during regular coil shop QC inspection. YY Analysis: WHY - Leaks and hairpin free-length damage & deformation (see Table 1.0) WHAT 1. Handling of coils in the Sub-cooler & Header tube results to damage 1.1. Operators are handling the coils in the headers during processing & movement. 1.1.1. Coils have almost no provision (side rails) for handling during assembly process in the shop-floor. (see Table #2.0 ) Retrain CS operators & coaters on handling and emphasize on not holding on to sub-coolers. 1.2. Damage during forklift transport or bumped by forklift while in staging area Design special rack for coils Study provision of fence in coil shop staging area. 2. Header tubes vibrate during transport and operations 2.1. Poor clamping/support design of header tube assemblies. Product engineering is now providing header tube clamps. WHO WHEN

PRODUCTION

CS-Nov 14 Done CC-Nov 18

MFG ENGG/ PRODUCTION MFG ENGG

Mar 10 Jan 10

PRODUCT ENGG PRODUCTION/ MFG ENGG

Nov 9 Done 1st Wk Dec

3. Expander Machine yields poor swaging (see Table 5.0) 3.1. Machine Set-up -Ongoing study and analysis on the root-cause 3.2. Coil orientation -same 4. Extra Deep Swaging in brazing area extends up to the endplate collar 4.1. Manual swaging tool is not standardized-some are too lengthy (see Table 4.0). 4.1.1. No swaging design rule Swaging rule defined and to be put into CS spec. Manual Swaging tool to be standardized and to be put into spec. Best Partner expander machine with 7mm swaging depth is ongoing reduction of swage depth as per design rule. 4.2. Manual swaging of braze operator 4.2.1. Expander machine is not swaging/flaring all tubes 4.2.1.1. Material Problem Primarily happens on Mettube material Get more data for the comparison between vendors. Only Sumitomo is running now. 4.2.1.2. Machine Problem same as above4.2.2. Operator widens hairpin free-length opening to accommodate header process tubes
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QC/MFG ENGG/ PRODUCTION MFG ENGG

Nov 19 Dec 12

PRODUCTION / MAINTENANCE

Nov 23

QC /PRODUCTION

Nov 2309

4.2.2.1. Header process tubes are not centrally aligned with the hairpin free-length opening (see Table 3.0) 4.2.2.1.1. Header Process tubes moves/deforms/misalign during brazing CS will ensure alignment of feeder tubes in endplates before brazing. This will be additional minor process in brazing area. 4.2.2.1.2. Header main tube bore spacing are not accurate 4.2.2.1.2.1. Operator skill in manual drilling station is poor (see Table 2.0) Long Term - CNC Punching machine to arrive Jan10 Immediate - Will be addressed by 4.2.2.1.1 action 5. Endplate holes ID variation 5.1. Tool wear out Issue GO-NO-GO pin to CNC operator to check endplate holes ID during FPI and in process. Fab QC to approved (by random inspection per batch) all batch of endplate submitted to CS Fab shop to provide tool life monitoring and control.

PRODUCTION/ MFG ENGG

Nov 16

MFG ENGG

Jan 10

MFG ENGG QC / FAB&CS PRODUCTION FAB / PRODUCTION

1st Wk Feb Immediate 2nd Wk Dec

Conclusion:
!! "a#$e$ in red$ need to %e addre$$ed&

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Table 1.0 Photos of Hairpin Free-Length Damage / Deformation

#1 Free-length deformation. Note the lack of swage section in the stem in the upper tube. CAC1-3 Assembly Line

#2 Free-length damage CAC1-3 Assembly Line

#3 Free-length deformation CAC1-3 Assembly Line

#4 Process tube pushed all the way of the entire hairpin free length. Note, there is no more visible swage section in the stem. This is similar to #8 below CAC1-1 Assembly Line

#5 Leak @ the endplate collar area. Field- Log-In S3G-AA-048-2009

#6 Free-length deformation Field- Log-In S3G-AA-096-2009

#7 Hairpin leak at end plate junction. Field - Log-In S3G-AA-106-2009

#8 Leak @ the endplate collar area. Note, there is no more visible swage section in the stem. Field -Log-In S3G-AA-105-2009

#9 Leak @ the endplate collar area. Field -Log-In S3G-AA-096-2009

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Table 2.0 Photos of process punched holes in the header main tube

1't( (o!e )'*in +rom t(e (o!e ,1- "enter i$ a!read. /10161 a2a. +rom t(e "enter&

Ho!e ,1 re+eren"e po$ition

13t( (o!e )'6in +rom t(e (o!e ,1- "enter i$ a!read. /303'1 a2a. +rom t(e "enter&

1*t( (o!e )'4in +rom t(e (o!e ,1- "enter i$ a!read. /1041 a2a. +rom t(e "enter&

5oi! Hand!ing in 5S

Table 3.0 Photos of process tubes misaligned with the hairpin free-length port.

6ro"e$$ t#%e$ not a!igned 2it( t(e (airpin +ree-!engt( port$

6ro"e$$ t#%e$ not a!igned 2it( t(e (airpin +ree-!engt( port$

6ro"e$$ t#%e$ not a!igned 2it( t(e (airpin +ree-!engt( port$

Table 4.0 Photos of non-standard swaging/flaring tools used in CS.

Non-$tandard $a2ing0g!aring p#n"( too!$ #$ed in 5oi! $(op %razing area&

Table 5.0 Photos of good and bad swaging before brazing.

Bad S2aging& S2age in one $ide o+ t(e t#%e on!.&

6er+e"t S2aging & 7!aring

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