Abstract: A method of assembling a heat exchanger unit (12) that involves an expansion technique for securing a heat exchanger tube (18) to a number of fins (24) without physical intrusion into the tube passage. The method includes forming the tube (18) to have substantially parallel tube portions (26). Pairs of tubes portions (26) may be connected by a bend or an elbow (28) to yield a serpentine tube configuration. Each of the fins (24) is formed to include one or more apertures that are sized to receive the tube portions (26). The fins (24) are then arranged to form a fin pack (22), so that their apertures are aligned to form an aggregate passage through the fin pack (22). The tube portions (26) are then inserted into the aggregate passage, such that the elbow (28) (if present) and/or the ends of the tube (18) remain outside the fin pack (22).

Abstract: A machine includes a casing disposed in a housing for receiving one or more tubes and a number of fins engaged around the tubes. A frame is slidably received in the housing, and one or more rods are secured to the frame and moved to engage into and to expand the tubes to engage with the fins when the rods are moved toward the tubes. A bracket and a seat have one or more pipes slidably received in the barrels for slidably receiving the rods and for preventing the rods from being bent. The rods each includes a mold piece for further expanding the tubes.

Abstract: An apparatus for holding a heat exchanger core during a manufacturing process is disclosed. The core includes a first and second side support member disposed on opposite sides of an assembly of a plurality of interleaved tubes and fins and fluid manifolds on opposite ends of the tubes. The apparatus includes a pair of nested clamps. One clamp is disposed over the side supports and the second is disposed over the fluid manifolds. The clamps are easily placed over the core and easily removed after brazing.

Abstract: A core builder machine (10), including an elongated table (12) on which the cores are supported and transferred to the various assembly portions of the machine (10). A plurality of heat exchanger tubes (18) are fed from a tube magazine (16) by a tube dispenser assembly (14) onto the table (12) where they are indexed and adapted to receive a plurality of serpentine fins (36) between a pair of adjacent tubes (18) to form an intermediate core assembly (42). The intermediate core assembly (42) is transferred downstream by a plurality of slides (56, 58) to a core compression section (70) where the intermediate core assembly (42) is compressed. After the intermediate assembly (42) is compressed the header attachment mechanism (75) moves into contact with the sides (56, 58) of the core to attach the headers and form a completed core assembly (110) that can be removed and then brazed.

Abstract: A heat exchanger, especially a heating or cooling radiator for a motor vehicle, has a tube bundle consisting of oval or oblong tubes which extend through a matrix of cooling fins. End portions of the tubes are introduced into holes in a header plate, with a compressible sealing gasket being interposed, the gasket having collar portions surrounding the tube end portions, and the latter having an oval or oblong cross section. The major axis of each tube end is equal to the major axis of the body of the tube, while the minor axis of the tube end is greater than the minor axis of the body of the tube as a result of the tube having been expanded or flared during the assembly of the heat exchanger.

Abstract: A fixture for supporting a heat exchanger coil within a tube expander apparatus. The back wall of the fixture contains a series of spaced apart vertically disposed stationary slats. A moveable frame is slidably mounted in the back wall which contains a series of vertically disposed spaced apart moveable slats that are interspaced between the stationary slats. The slats coact to present an adjustable flat support surface to a coil mounted in the fixture that can be adjusted to accommodate different size coils. The front door of the fixture contains a similarly adjustably wall that coacts with the back wall to fully support a coil in the fixture as the tubes of the coil are being expanded.

Abstract: An apparatus for forming heat exchanger core assemblies having a plurality of generally elongate tubes seated in uniformly spaced openings in a pair of spaced parallel header members is disclosed. The apparatus includes a generally flat, horizontal support table and a pair of header carriers mounted for horizontal reciprocatory movement respectively toward and away from two opposed sides of the table. The apparatus further includes a pair of elongate, horizontally disposed guide members for locating and aligning a plurality of tubes with the respective openings in header members. Each of the guide members includes a base portion and a plurality of finger members, each finger member projecting in a first position vertically upwardly from the base portion. The guide member further includes a plurality of upwardly opening elongate, tube receiving slots between the finger members, the slots extending parallel to the adjacent side of the table.

Abstract: A heat exchanging tube assembling apparatus is adapted to a heat exchanger having an outer casing in which is arranged a partition plate formed with holes through which heat exchanging tubes, each having a U-shape in an outer appearance, are inserted from an open end side of the casing in a full automatic manner. The heat exchanging tube assembling apparatus comprises a tube grasping device for grasping a plurality of U-shaped tubes in a lump at a working position, a tube positioning device for positioning the grasped tubes to positions from which the U-shaped tubes are inserted into the holes formed to the partition plate, a tube taking-out device for sequentially taking out one by one the U-shaped tubes grasped by the tube grasping device, and a tube feed device for feeding the taken-out tubes toward the partition plate and inserting the tubes into the holes of the partition plate.

Abstract: An apparatus for expanding an existing repair sleeve in a steam generator to permit a new repair sleeve to be installed. The apparatus includes a variable cross-section elongated cylindrical capsule adapted to be positioned within the existing repair sleeve and an explosive charge inside the capsule whereby detonation of the charge expands the existing repair sleeve to permit the new repair sleeve to be installed. The variable cross-section of the capsule permits the explosive force to be "tuned" so that the existing tube expands evenly along its entire length, including the hard to expand ends of the existing sleeve, without overexpanding the tube. In the preferred embodiment, the apparatus includes a conduit attached to one end of the capsule and at least one sleeve position indicator associated with the conduit. The sleeve position indicator associated with the conduit may be a predetermined index mark on the outer surface of the conduit, a hard stop located between the conduit and the capsule or both.

Abstract: An apparatus is provided for removing the severed end-portions of boiler tubes installed and retained in a boiler header without consequential boiler header metal damage and in a manner whereby a compression gap of uniform width is machined throughout the length and thickness of each retained boiler tube end-portion selected for removal, the machined boiler tube end-portion is subsequently compressed to significantly close the machined compression gap and reduce the tube end cross-sectional circumference, and the compressed tube end is withdrawn longitudinally from engagement with the boiler header tube-mounting bore.

Abstract: An apparatus assembles a heat exchanger core having first and second side plates. The first and second side plates cooperate with first and second end plates to sandwich a plurality of layered tubes and fin plates therebetween. The apparatus includes a lifting mechanism for stacking the tubes and fin plates with respect to one another to define a layered stack having opposite sides and opposite ends. A side plate assembling mechanism associates the first and second side plates on opposite sides of the layered stack. An end plate assembling mechanism associates the first and second end plates on opposite ends of the layered stack.

Abstract: An apparatus for repairing cracked core spray supply piping in a boiling water reactor vessel includes a pair of clamps extending circumferentially around the piping on opposite sides of a crack and a preloading mechanism urging the clamps toward one another to apply and maintain an axially compressive load on the piping tending to close the crack. For vertical sections of core spray supply piping, the clamps are secured at vertically spaced locations with each of the clamps including a first jaw extending circumferentially around a first portion of the piping and including a first opening oriented substantially parallel to a longitudinal axis of the piping and an elongate passage or channel oriented substantially perpendicular to and in communication with the first opening.

Abstract: A method for forming a heat exchanger is disclosed. The method includes the steps of forming a plurality of generally planar plate members from a sheet of material, each of the plate members being connected to an adjacent plate member by a deformable link. The method further includes forming a plurality of tube members by folding the plurality of plate members at the deformable links, inserting a fin member between adjacent tube members, and compressing the plurality of tube members and fin members under a predetermined load to form a heat exchanger core. The method also includes the steps of bending the folded deformable links against the core and brazing the core at a predetermined temperature. A heat exchanger manufactured according to this method is also disclosed.

Abstract: A method of manufacturing a heat transfer tube (10) having an external surface that is configured for enhanced heat transfer performance in both refrigerant evaporating and condensing applications. The tube is suitable for use in, for example, shell and tube type air conditioning condensers, flooded evaporators, falling film evaporator, or a combination of flooded and falling film evaporator. The tube has at least one fin convolution (20) extending helically around its external surface (13). A pattern of notches (30) extends at an oblique angle (.alpha.) across the fin convolutions at intervals about the circumference of the tube. There is a split spike (22) having two distal tips (23) between each pair of adjacent notches. The fin convolution, notches and split spikes are formed in the tube by rolling the wall of the tube between a mandrel and, first, a gang of finning disks (63), second, a notching wheel (66) and third, a splitter wheel (67).

Abstract: A rod driver gear for a tubing expander is operable to drive a rod having a circumferentially extending outer surface with a plurality of grooves extending traversely across a longitudinal axis of the rod. The rod driver gear includes an annular body rotatably mounted to a frame of the tubing expander and connected to a power source of the tubing expander. The annular body has a ridged outer diameter surface. Each ridge of the outer diameter surface is dimensioned to extend into the grooves of the rod to sequentially engage the grooves of the rods when the power source rotates the annular body to thereby move the rod along the longitudinal axis of the rod. In a preferred embodiment, the outer diameter surface of the annular body has a plurality of grooves extending across the surface, and a plurality of pins are inserted through a bore into the grooves. A portion of the pins extends from the grooves to constitute the ridges.

Abstract: Heatsink devices are formed by attaching a plurality of fin members to a planar base member. A primary strip of thermally conducive material forms base members which are assembled with fin members formed from a secondary sheet of thermally conducting material. Each fin member is secured to a respective portion of the primary strip. The primary strip is advanced with the fin members secured thereto to be parted off to provide the heatsink devices. The synchronization of the forming of fins with the assembly reduces manual input to the manufacturing process, negates the need to hold stocks of preformed fins and increases design freedom with respect to dimensions of the heatsinks being formed.

Abstract: A gap-cutter tool assembly for machining a longitudinal gap in an installed boiler tube is provided with clamp elements that engage the interior surface of the installed boiler tube, a cutter head track that provides a straight line cutting path within the tube interior and in the presence of different tube interior diameters, and a cutter head that co-operates with the cutter head track and that has different elevational positions during the cutter head cutting and return strokes, and at the end of the cutter head return stroke.

Abstract: A method and apparatus is provided for removing the severed end-portions of boiler tubes installed and retained in a boiler header without consequential boiler header metal damage and in a manner whereby a compression gap of uniform width is machined throughout the length and thickness of each retained boiler tube end-portion selected for removal, the machined boiler tube end-portion is subsequently compressed to significantly close the machined compression gap and reduce the tube end cross-sectional circumference, and the compressed tube end is withdrawn longitudinally from engagement with the boiler header tube-mounting bore.

Abstract: A method of manufacturing a heat exchanger with a plurality of radiation fins which are stacked on a plurality of hairpin tubes or straight tubes includes the steps of clamping bent portions of the hairpin tubes or one ends of the straight tubes in such a manner as to arrest axial movement thereof by a clamp having at least one pair of clamping jaws, press fitting a plurality of mandrels respectively into openings of the hairpin tubes, or openings of the straight tubes which are opposite to the clamped ends to form expanded portions of a predetermined length, moving a plurality of grippers, each of which includes a plurality of gripping strips with their longitudinal axes coaxially aligned with the tubes, from a withdrawal position to an operative position in such a manner as to grip each of the expanded portions of the tubes, while maintaining a predetermined clearance between the adjacent gripping strips, and moving the mandrels within the tubes in such a manner as to expand the tubes through their entire l

Abstract: In forming a heat exchanger, a tube of the heat exchanger is expanded by a bullet, which is attached to a mandrel. The tube is projected from both end faces of a piled body formed by piling a plurality of fins. Each fin has a tube hole through which the tube passes. The fins and the tube are integrated by expansion of the tube. A first projected section of the tube, which is projected from one end face of the piled body and which has been expanded by the bullet, is held at a prescribed position. The bullet is pressed toward a second projected section, which is projected from the other end face of the piled body. As the bullet moves toward the second projected section, it expands the tube. The second projected section of the tube is allowed to contract during the tube expansion. An object of the present invention is to prevent adhesion of adjacent fins and irregularities in fin clearances between adjacent fins.

Abstract: A shot peening system for peening the tubes of a steam generator continuously generates a shot stream and withdraws the shot stream dispensing nozzle into a vacuum chamber in an end effector while repositioning the nozzle for peening the next tube. A load tank forms an air lock for recycling shot recovered and cleaned by the vacuum system to a pressurized peen tank which feeds the recycled shot to a feed valve for mixing with a flow of compressed air to generate the shot stream. The pressure on the shot in the feed tank and the pressure of the compressed gas supplied to the feed valve are independently regulated to adjust the concentration of shot in the shot stream. The feed valve is constructed for ease of assembly and repair, and directs flow of a purge gas across the shot feed orifice and into a purge line which cycles shot and debris purged from the feed valve to the shot cleaning equipment on the vacuum side.

Abstract: A method for installing a tube repair sleeve in a tube at a selected location relative to a tube defect or a tube support. The method includes using a hydraulic expander having at least one expandable bladder. The expander includes a stud having at least one conduit formed therein and a plurality of slidable expandable bladders mounted on the stud for radial expansion, each of the bladders in fluid communication with the conduit. A detector means is mounted on the expander and responsive to tube supports and defects in the tube. Finally, a control system is electrically connected with the detector means and operative to control the expansion of the bladder in response to signals received from the detector means.

Abstract: A process for producing a flat heat exchange tube having parallel refrigerant passages in its interior and comprising flat upper and lower walls, opposite side walls and a plurality of reinforcing walls connected between the upper and lower walls, extending longitudinally of the tube and spaced apart from one another by a predetermined distance, using a rolling mill including a central work roll and a plurality of planetary work rolls arranged around a portion of the periphery of the central work roll and spaced apart circumferentially thereof, the central work roll being formed with parallel annular grooves in the periphery thereof.

Abstract: An apparatus for manufacturing a needle-rib heat-exchanger construction including a band which is wound around a tube. Initially, cuts are formed on both sides of an elongate band and thereafter the band is passed through a series of engaging former wheels. A bottom part is formed into the band and top portions of the band are folded onto the bottom part. Needle-shaped ribs are formed to project from the top portions and are placed at an angle in relation to one another. The band with needle-shaped ribs is then mounted on the tube.

Abstract: An evaporator heat transfer tube (10) for use in a heat exchanger where heat is transferred between a fluid flowing through the tube and a fluid flowing around the exterior of the tube and where the fluid external to the tube boils during the heat exchange process. The tube has a plurality of helical fins (20) extending around its external surface (13). A pattern of notches (30) extends at an oblique angle (.alpha.) across the fins at intervals about the circumference of the tube. A spike (22) having a flattened distal tip (23) is formed between each pair of adjacent notches. The maximum width (W.sub.t) of the spike at its tip is greater than the width (W.sub.t) of the base portion of the fin and is of a width sufficient to overlap with and contact the distal tips of spikes in adjacent fins on both sides thereof, thus forming reentrant cavities between the adjacent fins and under the overlapping tips.

Abstract: A method of manufacturing a heat exchanger using fluidic expansion, the heat exchanger having tubing sections interconnected to form at least one circuit for transporting a first heat transfer fluid and conductive fins secured to the circuit for increasing the surface area thereof and increasing the heat transfer between the first fluid and a second fluid flowing among the fins. The tubing sections are positioned in a predetermined manner and the fins are disposed therewith and along the length thereof. The inlets and outlets of the tubing sections are then interconnected to form said the fluid circuit. Next, the fins are secured in place so as not become damaged during the sealing of the interconnections, which follows immediately thereafter. Finally, the entire circuit is expanded to enmesh said fins by enclosing the volume of the circuit and introducing an expansion fluid therein at a pressure which surpasses the tube yield strength of the tubing and causes the walls thereof to expand radially outward.

Abstract: A metallic finned tube, in particular for heat exchangers, which includes multiple integral fins helically extending on the outside, with the n fin run starts starting at the start of the tube and are evenly distributed around the tube periphery. The finned tube has a number of fin run starts n.gtoreq.4 with at least one group having at least two side-by-side oriented fin run starts (A.sub.1, A.sub.2 or rather A.sub.3, A.sub.4 . . . ).

Abstract: A method and tool for installing a baffle in a tubular member, such as a heat exchanger manifold. The method and tool are adapted to use a baffle having a closed base that acts to obstruct the flow of a fluid within the tubular member, and further having a sidewall extending axially from the perimeter of the base so as to form a recess in the baffle. The tool is generally composed of a sleeve having an elastically and radially deformable end, such as a number of cantilevered members adapted to be elastically bent radially outward. Radially outward deformation of the sleeve enables the sleeve to securely grip the baffle, maintain the orientation of the baffle during its insertion into the tubular member, and then plastically deform the sidewalls of the baffle in order to secure the baffle to the wall of the tubular member.

Abstract: An apparatus for expanding the tubes in a heat exchanger of the plate fin and tube type. The expander is of the type that expands the tubes by driving a "bullet" through the tube with the bullet being attached to and driven by an expander or bullet rod. The apparatus has a sensor positioned so as to be able to measure the compressive force on the expander rod. The output of the sensor is proportional to the force exerted on the rod and can be used to provide an alarm or safety shutdown of the apparatus upon the sensing of excessive force on the expander rod. The sensor output can also be used for quality and process control.

Abstract: Method for expanding tubular members, such as U-shaped heat transfer tubes having ends thereof located in the confined space adjacent the curved sides of the bowl-shaped lower plenum of a typical nuclear steam generator. The apparatus includes an elongate mandrel having a flow channel therethrough in communication with a resilient tubular bladder surrounding the mandrel. The bladder is flexible about its longitudinal axis due to the ribbed construction of the wall thereof. The mandrel includes a plurality of segments, adjacent ones of the segments interconnected by a ball-and-socket joint therebetween, so that the segments swivel about respective ones of the ball-and-socket joints. Thus, the mandrel and the expandable bladder connected thereto are flexible rather than rigid in order to be easily inserted into the tube ends located adjacent the curved sides of the bowl-shaped plenum and in order to easily traverse the upper U-bend portion of the tube.

Abstract: Method of restricting transverse displacement of a nuclear heat exchanger tube support plate during a transient event, the support plate having a plurality of holes therethrough for passage of respective ones of a plurality of heat transfer tubes. The method includes radially expanding the tube adjacent the first side of the support plate to define a first expanded region thereat, the tube being expanded to a diameter greater than the diameter of the hole formed through the support plate. The method further includes radially expanding the tube adjacent the second side of the support plate to define a second expanded region thereat, the tube being expanded to a diameter greater than the diameter of the hole formed through the support plate. The first expanded region and the second expanded region coact to restrict transverse displacement of the support plate because the support plate is firmly captured between the first expanded region and the second expanded region.

Abstract: A device for continuously forming a heat exchanger that has a helically wound fin tube coil formed by a plurality of wraps includes a rotationally driven mandrel with a central axis and a plurality of forming corners equiangularly disposed about and displaced from the central axis. The rotation of the mandrel is about the central axis in order to wind the fin tube coils onto the mandrel. A forming block is operably rotationally coupled to the mandrel and rotates with the mandrel. The forming block is also slideably engaged with the mandrel for axial translation a selected distance with respect to the mandrel. The forming block guides the winding of the fin tub coils onto the mandrel. An actuator is operably coupled to the forming block and causes the axial translation of the forming block.

Abstract: A machine for corrugating preformed plates that form the core element of a heat exchanger. A fold forming mechanism imparts an initial fold in the deformable links joining a series of preformed plates received from an external source. A gathering mechanism gathers the folded series of preformed plates to produce a flow of pairs of mating plates. Precut lengths of corrugated fins are then inserted between joined adjacent pairs of mating plates and a cut-off mechanism severs the deformable links of preselected pairs of links joining pairs of mating plates to separate individual core elements from the flow of plates.

Abstract: This invention concerns the manufacture of helically corrugated conduit having at least a portion of its length corrugated in the form of at lease one helix. The method includes the driving of a smooth walled tube into a forming head having forming wheels which engage the outside of the tube and the wheels are at an angle relative to the longitudinal axis of the tube. The forming wheels form the helical spiral as part of a cold rolled forming process. More than one helical spiral can be formed simultaneously using a multiplicity of forming wheels.

Abstract: The described apparatus produces an end closure for a pipe that forms part of a heat exchanger. The apparatus includes a frame, with first and second sides. A tubular through-channel has an opening on the first said that is delimited by a side surface extending around the opening. It is possible for a pipe which is intended to be closed, to be introduced into the tubular channel from the second side. A press tool executes a reciprocal motion through the channel. The press tool presses an end closure blank into the channel opening. A method for producing an end closure for a heat exchanger pipe also is described. The method comprises the measures of introducing a pipe into a channel in a frame. An end closure blank is pressed into the through-channel and on into the pipe.

Abstract: A method for mounting a hairpin tube to a heat exchanger body where a rod member is inserted into at least one of plural through holes defined in each of plural radiation fins stacked in the heat exchanger body. The rod member is further extended through the associated through holes of the stacked radiation fins. The hairpin tube is then inserted into the corresponding through holes.

Abstract: A tube expanding assembly expands a plurality of tubes used in combination with a plurality of fins and end sheets to form a heat exchanger, the tube expanding assembly includes a nest plate secured to the base wherein the nest plate holds the tubes thereon, a bolster cylinder extendable between the base and the nest plate for moving the nest plate relative to the base, a ram support disposed above the base, a ram plate secured to the ram support, a ram cylinder depending from the ram support and secured to the ram plate wherein the ram cylinder moves the ram plate relative to ram support, a plurality of expansion rods depending from the ram plate wherein each of expansion rods is extendable through each of the tubes such that the tubes engage the fins and end sheets, and a plurality of transducers, each of the transducers are associated with each of the bolster cylinder and the ram cylinder such that the transducers create signals identifying position of each of the ram plate and the nest plate.

Abstract: An apparatus provides automatic lacing of hairpin tubes through the holes of a heat exchanger fin stack. This apparatus includes a plurality of identical extendable guide rods, each positioned in approximate alignment to engage an open end of a respective heat exchanger tube which is positioned adjacent to a respective fin stack hole. The plurality of guide rods are extended in unison through the holes of the heat exchanger fin stack to positions within the open ends of the hairpin tubes. Lead guides are located toward the end of each guide rod. The lead guides have forward and backward tapered surfaces extending from a central portion of maximum diameter. The lead guides ensure that the holes in the individual fins are moved into coaxial alignment with the guide rods as they travel through the fin stack. Once the guide rod ends are within the open ends of the hairpin tubes, self-aligning engagement fingers on each guide rod lead end expand to engage the internal diameter of a respective hairpin tube.

Abstract: To produce a corrugated fin suitably used to fabricate heat exchangers such as radiators, condensers of the air conditioners, etc., for automobiles, a toothed roller for forming a corrugated fin has circumferential teeth comprising a tooth tip having a concavity, a tooth bottom having a convexity, and a tooth slope having a louver cutting edge between the tooth tip and the tooth bottom, wherein a top of the convexity of the tooth bottom is located at a forward offset from a center line of the tooth bottom with respect to a direction of rotation of the roller.

Abstract: A method of removing a metal plug from a conduit includes the steps of simultaneously applying a static pull force and repetitive impulses to the plug. The method is particularly suited to removing a plug from a heat exchanger tube in a nuclear powered steam generator. A tool for practicing the method on such plugs includes a first hydraulic actuator for first moving an expansion member out of engagement with an interior plug wall, a second hydraulic actuator capable of attachment to the plug for applying a static pull force to the plug, and an arrangement connecting an air impact tool to the second hydraulic actuator for applying, simultaneously with the static force, high-frequency impulses to the plug entirely through solid members.

Abstract: A method and a device for the draw expansion of metal tubes of oval cross-section uses expansion elements drawn unidirectionally through metal tubes by means of draw elements. The expansion elements are fastened to the draw elements by suspension devices which have a hammer-like contour. The draw elements are preferably made of a rod-shaped material. An apparatus of the invention is an apparatus for mechanically expanding metallic tubes, in particular tubes in heat exchangers. Each individual tube to be expanded is held in at least one holding device and passed through by a drawing mandrel with an expanding element. To prevent jamming of the expanding element in one of the holding devices, the holding devices are provided with lateral guides which are resiliently compliant outward in the radial direction. When the expanding element passes through the metallic tube, the tube is expanded in the radial direction.

Abstract: A tube puller, also called a traveler, removes tubes from the tube sheet of a heat exchanger for replacement. The tubes must first be broken free from the tube sheet and moved several inches by another device not associated with the traveler. The traveler includes a frame mounting a hydraulic motor. Inside the frame, a single driver mounted on the shaft of the motor is a wheel having a toothed circumference. The teeth of the driver engage one side of the tube to be removed. An unpowered idler is positioned on the opposite side of the tube from the driver. An actuator may move the idler selectively toward and away from the driver for altering the nip between the driver and idler to initially receive the tube. The actuator then presses the idler against the opposite side of the tube, holding the tube against the driver, but has no power to advance the tube longitudinally. Together, the idler and driver apply lateral forces that tend to deform the tube and may crush the tube completely as it is pulled.

Abstract: A hydraulic expander assembly for installing a tube repair sleeve in a tube at a selected location relative to a tube defect or a tube support. The apparatus includes a hydraulic expander having at least one expandable bladder and adapted to receive the sleeve thereon. The expander includes a stud having at least one conduit formed therein and a plurality of slidable expandable bladders mounted on the stud for radial expansion, each of the bladders in fluid communication with the conduit. A detector is mounted on the expander and responsive to tube supports and defects in the tube. Finally, a control system is electrically connected with the detector and operative to control the expansion of the bladder in response to signals received from the detector.

Abstract: An elliptical cross section tube of novel construction that is capable of being expanded by a conventional conical tool of the type used to expand round cross section tubes. The tube is also reinforced by integral internal webs. The unexpanded tube cross section has concave lengthwise channels and concave internal webs that are all internally tangent to a circle representing a cross section of the expansion tool's conical head. As the head of the tool is pushed through the tube, it pushes the channels out into the fin hole while flattening the webs. The tube is thus mechanically bonded to the tube, and is left with a pair of internal reinforcing webs.

Abstract: The present invention relates to filler tubes and, more particularly, to fuel filler tubes and methods of attaching them to automobile fuel tanks. The fuel filler tube of the present invention includes an inlet tube, a retainer member, sealing means and a fuel tank having a downwardly extending diameter portion. The retainer is disposed over the downwardly extending diameter portion and adhered to the tank. The inlet tube is then inserted into the fuel tank aperture until the inlet tubes annular flange engages the fuel tank's annular lip. A crimping tool is then inserted through the axial bore of the inlet tube and a plurality of bearings contained on the crimping tool are forced radially outwardly to thereby crimp the inlet tube and downwardly extending diameter portion together. The retainer member includes a plurality of recessed areas for hosting the expanded inlet tube and tank portions.

Abstract: A tube traveler and slitter for extracting a tube from a heat exchanger tubesheet and slitting the tube longitudinally into two segments includes two spaced apart deforming rolls having a nip between the peripheries defining a passageway. The periphery of each roll is serrated and has a cylindrical central portion of a larger diameter than the remainder of the periphery, and a cylindrical portion spaced from the central portion at each end of the roller, a truncated conical surface being between the cylindrical portions. The rollers extract and deform the tube into a configuration having a flattened central portion and a bulbous configuration at each edge. A rotary slitter blade is positioned for engaging and slitting each edge longitudinally. The axis of rotation of the slitter blades is downstream from the axes of rotation of the rolls.

Abstract: A tube-plugging assembly for sealing a leaking or damaged tube of a heat exchanger, either provisionally for later repair or permanently, comprises a plug, and an explosive charge and buffer subassembly disposed in the central portion of the plug. The charge and buffer subassembly is placed within the plug so as to leave an unoccupied space between the closed end of the plug and the end of the subassembly. The embodiment for provisional plugging comprises a plug having two to six grooves around its outer circumference for containing four to five annular rings of a gold-nickel alloy, and also comprises a plurality of female threads on the inside of the plug near the closed end. The embodiment for permanent plugging comprises a plug having two to six annular prominences around its outer circumference. The buffer is of a ductile polyethylene resin that transfers the explosive power to expand the plug and also absorbs any explosion debris. A connecting cord connects the explosive charge to a remote detonator.

Abstract: A metalworking tool is capable of making internally grooved and externally finned heat exchanger coils from ordinary tubes in a single operation in which the tubes are expanded into bonding mechanical contact with external fins at the same time that grooves are formed in the inner surfaces of the tubes. The process is performed by a tool head having both expanding and groove forming tools mounted thereon. The expanding tool preferably comprises a hardened expansion ball which mechanically expands the tube with or without hydraulic or pneumatic assist. The groove forming tool may comprise a cutting point which scribes the tube, a roller which forges a groove, or any other suitable scribing or forging device. The groove forming tool may rotate or oscillate to produce nonlinear grooves and may form grooves during the in-going and/or out-going strokes of the tool.

Abstract: Apparatus for localized radial expansion of a ductile metal tube into tight engagement with a tube support sheet, e.g., for deformable member which is axially compressed by hydraulic pressure to effect radial expansion of the deformable member and the tube. The hydraulic pressure is multiplied to provide a relatively high force in a small diameter by connecting a plurality of pistons in series by rigid connecting rods having axial and radial bores for flow of pressurized fluid. The apparatus carries a probe for locating the position of the tube support sheet and a support member carrying an eccentric cam. Rotation by an operator of the support member, by rotation of a rod passing therethrough, causes the cam to frictionally engage the tube wall and wedge the support member in position to provide an abutment surface for contact by a stop member on the rod, thereby positioning the deformable member at the desired axial location to effect radial expansion of the tube.

Abstract: A tube traveler and slitter for extracting a tube from a heat exchanger tubesheet and slitting the tube longitudinally into two segments includes two spaced apart deforming rolls having a nip between the peripheries defining a passageway. The periphery of each roll is serrated and has a cylindrical central portion of a larger diameter than the remainder of the periphery, and a cylindrical portion spaced from the central portion at each end of the roller, a truncated conical surface being between the cylindrical portions. The rollers extract and deform the tube into a configuration having a flattened central portion and a bulbous configuration at each edge. A rotary slitter blade is positioned for engaging and slitting each edge longitudinally. The axis of rotation of the slitter blades is downstream from the axes of rotation of the rolls.