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Continual development of internal combustion engines requires greater performance from liquid coolants and heat exchangers to maintain optimal temperature. For the purpose of experimental testing of traditional, compact, and microchannel heat exchangers, a test facility has been designed, constructed, and utilized. The facility includes equipment and instrumentation necessary to create operating conditions and record data primarily for testing plate-fin brazed aluminum heat exchanger where heat is being transferred from liquid to air. Other arrangements of heat exchangers could be tested as well with some modifications. Initial tests were performed at several specified operating conditions for three liquids: water, a traditional glycol based Extended Life Coolant (ELC), and a new Glycol Free Coolant (GFC) in an attempt to characterize their heat transfer ability. Results of the tests found that the product of overall heat transfer coefficient and heat exchanger area (UA) was very similar for GFC and water, and it was less for ELC by a narrow margin of 1.3% difference on average. Uncertainty due to instrumentation accuracy was calculated to be 1.8% on average making the results overall UA unverifiable. Measured pressure drop across the heat exchanger which is proportional to required pumping power was found to be 13.5% higher for GFC than ELC at nominal conditions. The GFC offers similar heat transfer performance and marginally increased pumping power requirements compared to the traditional ELC. Due to similar heat transfer performance and the small effect of pressure drop, GFC would be good alternative to ELC due to its less toxic composition.

The HVAC&R industry is looking to transition from copper-aluminum heat exchangers to all-aluminum microchannel technology. The want for the transition stemmed from seeing the performance improvement of all-aluminum microchannel radiators in the automotive industry. Applications differ between the two industries; therefore, applying this technology for HVAC&R use must be validated. Research towards operating modes of an all-aluminum heat exchanger in a defined corrosive environment will provide the industry with a better understanding of heat exchanger design and heat exchanger material selection. The worth in this is preventing overdesign and producing more efficient heat exchangers. Furthermore, ASHRAE members and the corrosion community will find value in a defined corrosion system and corrosion test procedure. The information gained through past research has progressed assessment of material performance; however, the methods improperly simulate and expedite natural weathering. The most common method being used is the ASTM (American Society of Testing Materials) Sea Water Acetic Acid Test. The research discussed in this paper was focused on improving a standard corrosion system by implementing system modifications to simulate heat exchanger operation while performing a modified wet-dry cyclic test (e.g. ASTM G85 Annex 5). The goal is to produce results that are more representative of natural corrosion behavior and its forms. Current results were gathered from five of ten samples that underwent initial testing. Finally, possible improvements towards the chamber system and the test method, including the salt solution, are discussed.

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