The Effect of the Welding Technology on the Thermal Performance of Welded Finned Tubes Used in Heat Exchangers

Due to the use of welded finned tubes in heat exchangers, gas blocks are characterized by very good electric energy production performance, and their reliability can reach 98%. Finned tubes used in heat exchangers are usually welded. Such tubes should be characterised by the following properties: high thermal performance, good resistance to high-temperature corrosion in a flue gas atmosphere, and appropriate joint strength and hardness. The most popular technology for welding finned tubes is MAG. MAG-welded joints are characterised by considerable spattering, weld discontinuities (up to 60%), and non-axial fin alignment. Such irregularities result in a considerably reduced heat flux due to the heat transfer resistance occurring in the welded joint. It has been shown that with weld discontinuities of 20%, the thermal performance of welded finned tubes reduces considerably. This paper proposes the possibility of welding finned tubes with a laser. The thermal properties of laser-welded finned tubes were compared with those of MAG-welded tubes. It was found that the thermal performance of welded finned tubes was three times higher than that of plain tubes. However, the thermal performance was not found to be affected by the welding technology. The correct heat flow at the level of 95% occurs in the tube/fin joint even with joint penetration of 0.01 mm, however, the absence of metallic continuity in a joint results in a drastically reduced thermal performance (by 50%) and the overheating of fins, which affects their durability.