Nélia M. Silva

Heat pumps are increasingly becoming a key solution in the quest for decarbonization, offering a significant advantage over traditional boilers due to their superior energy efficiency. Not only can heat pumps provide both heating and cooling, but they also achieve thermal efficiencies exceeding 500%, which can seem to defy conventional expectations. The outdoor unit of a heat pump consists of about twenty main components, one of which is a complex network of copper pipes and sheets welded to valves, connectors, and other fittings. This set involves over thirty welded joints, highlighting a significant opportunity for reducing manufacturing time through process optimization. Copper is a critical material extensively used in various applications due to its excellent thermal and electrical conductivity. However, these very properties make welding copper particularly challenging, especially when aiming to automate and streamline industrial processes. Traditionally, connecting copper pipes and fittings is done through brazing, yet, alternative methods such as LASER welding, electron beam welding, resistance welding, friction welding, and ultrasonic welding also exist. This study focuses on the ultrasonic welding of copper, aiming to identify the optimal parameters that maximize the mechanical strength of overlapping joints and ensure effective tube sealing. Experimental results showed that for copper sheets, the best outcomes were achieved with a welding time of 3 s and a pressure of 6 bar. For tube sealing, the optimal conditions were a welding time of 3 s and a pressure of 4 bar. For both scenarios, the same variables were used, retention time of 0.62 s, initial pressure of 2 bar, retention pressure of 2 bar and sonotrode rising pressure of 3 bar. The analysis reveals that ultrasonic welding of copper can achieve both robust mechanical strength and reliable sealing, making it a promising technique for industrial applications.

In heat pumps and refrigeration systems, copper parts play a crucial role. Since heat pumps for space and water heating work under high pressure and are susceptible to vibrations, it is crucial to perfectly weld the copper pipes and heat exchangers to avoid system failures and prevent the leakage of the circulating refrigerants, which are harmful to the environment. The welding of the copper pipes is usually performed by the brazing process in a furnace. The components are subjected to a period of approximately 50 min inside a continuously open oven, varying the temperature from 710 °C to 830 °C. The oven inlets and outlets are protected by nitrogen curtains to guarantee a suitable internal environment and prevent the contamination of the gas inside the oven. This work analyses which welding methods are most suitable for welding copper, the best joint shape, process time, brazing specimens of a copper alloy, tightness tests, and mechanical properties and composition of the welding samples. From the tests carried out, the appearance of small and large defects is reduced by using a 1 mm thick external ring of filler material and a brazing temperature of 820 °C.