Radiators are cast from aluminium alloy, an alloy that possesses excellent casting properties, is highly resistant to corrosion and has good mechanical characteristics. The melting of the alloy is carried out in a gas fired aluminium furnace with a capacity of 10 t for melted alloys. The melt is processed and verified prior to the start of casting radiators. Before pouring out the melt from the casting furnace, the chemical composition of the alloy is verified, and the metallographic structure is also analysed if required. Casting radiators is carried out using high-pressure machines with a closing force of between 7,000 kN and 13,500 kN. The machines are equipped with electric resistance furnaces used for automatically maintaining the temperature of the melt. Each machine is equipped with automatic melt dosing, automatically lubrication of casting tools, a system for forced ventilation and filtering of particles and steam from the casting process, and automatic temperature control of the tool and hydraulic medium within the required limits. The radiator casting process is carried out by systematic control of casting parameters and subsequent quality control of the radiators themselves.
Assembling the radiators
Following casting process, the radiator columns are finish treated, assembled into radiator sections and an initial permeability test is carried out. The permeability test is carried out on the complete product. On these processing lines, the technical parameters for line operations are verified as well as the radiator columns and sections. Lines are equipped with closed-systems for filtering particles from the radiator treatment process.
In the next phase, a visual inspection of the assembled radiator is carried out and another verification relating to 100% impermeability of the radiator. This testing is carried out using 10 bars of air pressure. When required by customers and for particular markets we conduct testing at pressures of up to 30 bars.
The assembly process carries are
The assembly (formation) of radiator sections sized as required by customers is carried out in the assembly stage. When completely finished, assembled in accordance with customer requirements and once designated, the radiator sections are directed to the next production phase – colouring or pigmenting.
Colouring and packaging the radiators
The surface preparation process for colouring the radiator and the colouring processes itself is completely automated. All systems are a closed type exerting a minimal environmental impact from the varnishing chamber.
Prior to radiator colouring process, the external surface area of the radiator is cleaned of all impurities. Simultaneously to this process the chemical treatment of the radiator surface is carried out in order to achieve maximum corrosion stability.
In the next phase, application of the colour primer is carried out on the whole surface of the radiator. The colour primer is applied by electrostatic immersion of the radiator in a particular colour. The colour primer provides sufficient corrosion protection for the radiator.
The next phase is electrostatic application of a powder colour on the primer colour. After the application of the programmed layer of powder colour, a colour polymerisation process is carried out in a furnace.
Following a colour stabilisation period and final verification of each particular radiator section, the radiators are packed on the packaging line. The sides of the radiators are protected using carton covers, whereas the whole section is wrapped in heat-shrinking wrap. Each radiator section is designated by a barcode in order to identify it in the sales chain.
The radiator sections are placed on standardised pallets or if it's an order, their placed on specially designated pallets.