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Tests have been conducted to evaluate materials suitable for headers of CAB brazed aluminum radiators, particularly as concerns pressure cycle endurance. These tests were done on different alloy compositions, for both standard and proprietary versions from series 6000 and 3000, with or without post-braze heat treatment. The results from those tests have helped to evaluate the influence of various material characteristics over the pressure cycling resistance. In particular, they have shown that post-braze yield strength was not the only parameter to consider. It appeared also that none of the materials tested could give good results for all designs and test conditions, but, at least, this study has helped to state more precisely what the contents of a specification for an ideal material should be.

To answer new markets needs for radiators with thermal performance improved and packaging and weight reduced, we have, in the bounds of a coherent standard based on water tank interchangeability, developed two new cores sharing the smaller 42,5 mm water wide tank: a 34 mm mechanically assembled oval tube radiator featuring tubes with an axis ratio of 4, optimized fins and an innovative tube to header joining, this leading to 8 % more heat rejection than the previous oval tube core of our range with the same weight, a 34 mm two rows tubes touching aluminium brazed core using the 42,5 mm water tank owing to a new tube to header joining design, which offers the same heat rejection than copper brass cores of this range with 25 % less weight, and thrice the life span under cycled pressure (2,5 bar) of previous aluminium brazed cores of this range.