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In order to accurately predict the performance of a cooling module in an underhood environment, it is essential that the heat fluxes to the air from the various heat exchangers, such as radiator, condenser and charge air cooler, are modeled properly. Simulation models should therefore involve the prediction of the flow and temperature fields in both air and liquid side of heat exchangers. At Behr GmbH & Co., different simulation tools are successfully integrated in the development process to meet this goal. For underhood flow simulations, heat exchanger analysis programs are coupled directly with the flow solver. In order to verify the simulation a validation program has been set up based on the fact, that the air mass flow rate through the cooling module has a major influence on the performance of the radiator. Therefore, calculated air mass flow rates through the radiator were compared with the experimentally measured flow rates.

Aluminum has a number of features which make it superior to the other non-ferrous metals (copper and brass) normally used for radiators in the past. Apart from the low specific weight, there are additional advantages, such as outstanding heat conductivity, strength, corrosion resistance and convenient forming and processing qualities. Brazed aluminum radiators with flat tubes and louvered serpentine fins are used for high horsepower engines and/or in confined spaces, while mechanically assembled round tube or oval tube radiators are preferred for smaller engines and/or where there is sufficient space. The excellent field results with car radiators have led to the use of aluminum radiators in trucks as well. More than 10 million fluxless brazed flat tube radiators with serpentine fins have been manufactured by Behr since 1975. Serial production for trucks was started in 1988.

A high efficiency lightweight heat exchanger has been developed for water jacket cooling of engine oil in heavy commercial vehicles. This heat exchanger is comprised of aluminum construction, and utilizes recent developments in heat exchanger technology to obtain high heat rejection, low parasitic loss, and superior strength. This new development offers significant advantages over today's stainless steel oil cooler technology. Specifically, a 15-20% increase in performance is typical, while a minimum of 50% weight savings is expected. This innovation has been released for high volume production, and represents a major benefit for our customers.