Ecor International components in air conditioning systems

The company contributed to the production of Carel customer's ejectors for the regulation of refrigerant gas. The complexity of the project was linked to the need to weld three different types of steel.

Welding of different types of materials for the production of a single component is a complex activity that requires specific knowledge of the process because different metallurgical and physical characteristics can easily lead to defects in the final result.

The project

Manufacturing components without these imperfections was one of the challenges of the project on which Ecor International recently worked in collaboration with the customer Carel. It operates in the design, production and global marketing of technologically advanced components and solutions (hardware and software) to achieve high energy efficiency performance in the control and regulation of equipment and systems in the air conditioning (“HVAC”, Heating, Ventilating and Air Conditioning) and refrigeration markets.

The components made by Ecor International installed in the Carel customer’s valves.

Ecor International, specialized in the production of highly complex critical components also for the air and water treatment sector, has produced some parts of the customer’s ejector. This is intended for equipment and systems in the air conditioning and refrigeration markets. Ejectors, in particular, are used to increase the efficiency of CO2 refrigeration systems: they exploit the energy of the high-pressure fluid flowing through a nozzle to transport and compress another fluid that has a lower pressure. For this reason, they must withstand the high pressures to which they are subjected when the systems are in operation.

Metallographic analysis of the weld.

The activities of Ecor International

For this project, Ecor International carried out complex laser welding activities. The company had to weld three types of stainless steel to produce the ejectors. As consequence, they have different metallurgical and physical characteristics, also varying according to the temperature in different ways. This leads to changes in the welding process which can easily lead to defects.

In addition to this, a reduced weld penetration was required in order to limit the deformation of the material.

In order to meet these requirements, a preliminary phase has been carried out with various analyzes and technical evaluations. This phase allowed to establish the ideal welding parameters to obtain a high quality result: for example power, power variations, speed rate and protection of the weld pool with inert gas (argon). It was a laborious activity in which even small variations in the parameters led to significant benefits.

L’azienda ha contribuito alla produzione degli eiettori del cliente Carel destinati alla regolazione del gas refrigerante. La complessità del progetto era legata alla necessità di saldare tre tipologie di acciaio diverse tra loro.
The customer’s valves (courtesy of Carel)

In order to verify the quality of the work performed and the reliability of the parameters set, Ecor International performed destructive tests on the specimens and the final components with metallographic analysis, radiographs and tightness control with the Leak Detector.

The welding of heterogeneous materials is certainly not a new activity for Ecor International. Nonetheless, this project has made it possible to implement new control and monitoring procedures for the laser welding system that have now been made a standard, ultimately improving the company’s internal processes.