Corrosion resistant, alloy-coated charge air cooler

Abstract

A heat exchanger assembly for an automotive vehicle is provided. The heat exchanger includes at least one tube having a housing and at least one turbulator disposed inside the tube. The turbulator has an exposed surface. A corrosion resistant, thermally conductive, nonelectrolytic metallic alloy is deposited on the inner surface of the housing of the tube, and is also deposited on the exposed surface of the turbulator.

1 . A heat exchanger assembly for an automotive vehicle comprising:
 at least one tube including a tube housing having an inside surface;   wherein a corrosion resistant, thermally conductive, metallic alloy is deposited on said inside surface of said tube housing.   
   
   
       2 . The heat exchanger of  claim 1 , further comprising:
 at least one turbulator disposed inside said tube, said turbulator having an exposed surface;   wherein a corrosion resistant, thermally conductive, metallic alloy is deposited on said exposed surface of said turbulator.   
   
   
       3 . The heat exchanger of  claim 2  wherein said corrosion resistant, thermally conductive, metallic alloy is one of Ni—P, Ni—P—Mo, Ni—Sn—P, Co—P, Co—P—Mo, Ni—Cu—P. 
   
   
       4 . The heat exchanger of  claim 2  wherein said tube housing of said at least one tube comprises an aluminum based material. 
   
   
       5 . The heat exchanger of  claim 2  wherein said turbulator comprises an aluminum based material. 
   
   
       6 . The heat exchanger of  claim 1  wherein said corrosion resistant, thermally conductive, metallic alloy is a corrosion resistant, thermally conductive, nonelectrolytic metallic alloy. 
   
   
       7 . The heat exchanger of  claim 2  wherein said corrosion resistant, thermally conductive, metallic alloy is a corrosion resistant, thermally conductive, nonelectrolytic metallic alloy. 
   
   
       8 . The heat exchanger of  claim 7  wherein said corrosion resistant, thermally conductive, nonelectrolytic metallic alloy is one of Ni—P, Ni—P—Mo, Ni—Sn—P, Co—P, Co—P—Mo, Ni—Cu—P. 
   
   
       9 . The heat exchanger of  claim 7  wherein said tube housing of said at least one tube comprises an aluminum based material. 
   
   
       10 . The heat exchanger of  claim 7  wherein said turbulator comprises an aluminum based material. 
   
   
       11 . A method of making a heat exchanger, comprising:
 providing a tube having an inside surface;   depositing a corrosion resistant, thermally conductive, nonelectrolytic metallic alloy on said inside surface of said tube;   providing a turbulator having an exposed surface;   depositing said corrosion resistant, thermally conductive, nickel metallic alloy on said exposed surface of said turbulator; and   fixing said turbulator to said tube.   
   
   
       12 . The method of  claim 11  wherein said corrosion resistant, thermally conductive, nonelectrolytic metallic alloy is one of Ni—P, Ni—P—Mo, Ni—Sn—P, Co—P, Co—P—Mo, Ni—Cu—P. 
   
   
       13 . The method of  claim 11  wherein said turbulator is fixed to said tube using a brazing process. 
   
   
       14 . The method of  claim 11  wherein said corrosion resistant, thermally conductive, nonelectrolytic metallic alloy is deposited on said tube and said turbulator before said turbulator is fixed to said tube. 
   
   
       15 . The method of  claim 11  wherein said corrosion resistant, thermally conductive, nonelectrolytic metallic alloy is deposited on said tube and said turbulator after said turbulator is fixed to said tube. 
   
   
       16 . A tube for a heat exchanger, comprising:
 a generally cylindrical housing comprising an aluminum based material, said housing having an internal deposited layer comprising a corrosion resistant, thermally conductive, nonelectrolytic metallic alloy;   at least one turbulator disposed inside said housing, said turbulator comprising a aluminum based material, wherein a corrosion resistant, thermally conductive, nonelectrolytic metallic alloy is deposited on said at least one turbulator.