SAE-J2679-2004-Charge-Air-Cooler-Leakage

SURFACEVEHICLERECOMMENDEDPRACTICEChargeAirCoolerLeakageSAETechnicalStandardsBoardRulesprovidethat:“ThisreportispublishedbySAEtoadvancethestateoftechnicalandengineeringsciences.Theuseofthisreportisentirelyvoluntary,anditsapplicabilityandsuitabilityforanyparticularuse,includinganypatentinfringementarisingtherefrom,isthesoleresponsibilityoftheuser.”SAEreviewseachtechnicalreportatleasteveryfiveyearsatwhichtimeitmaybereaffirmed,revised,orcancelled.SAEinvitesyourwrittencommentsandsuggestions.Copyright2004SAEInternationalAllrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystemortransmitted,inanyformorbyanymeans,electronic,mechanical,photocopying,recording,orotherwise,withoutthepriorwrittenpermissionofSAE.TOPLACEADOCUMENTORDER:Tel:[phone](insideUSAandCanada)Tel:[phone](outsideUSA)Fax:[phone]Email:[e-mail]:®J2679ISSUEDNOV20041.ScopeThisdocumentisapplicabletoallair-to-airchargeaircoolersusedwithinternalcombustionengines.1.1PurposeThisdocumentdescribesallowableairleakageandtestproceduresformeasuringairleakageinair-to-airchargeaircoolers.2.References2.1ApplicablePublicationsThefollowingpublicationsformapartofthisspecificationtotheextentspecifiedherein.Unlessotherwiseindicated,thelatestissueofSAEpublicationsshallapply.2.1.1SAEPUBLICATIONSAvailablefromSAE,400CommonwealthDrive,Warrendale,PA15096-0001.SAEJ1148—EngineChargeAirCoolerNomenclatureSAEJ1542—LaboratoryTestingofVehicleandIndustrialHeatExchangersforThermalCycleDurabilitySAEJ1597—LaboratoryTestingofVehicleandIndustrialHeatExchangersforPressureCycleDurabilitySAEJ1598—LaboratoryTestingofVehicleandIndustrialHeatExchangersforDurabilityunderVibrationInducedLoading2.1.2OTHERPUBLICATIONSTMCRecommendedPracticeRP331—ChargeAirCoolerIntegritySAEJ2679IssuedNOV2004-2-3.ObjectiveThisdocumentdescribesthecircumstanceswheresmallleaksinair-to-airchargeaircoolersareacceptableanddescribestestmethodstomeasuretheseleaks.4.BackgroundBrazedaluminum,air-to-airchargeaircoolershavebeenusedsincetheearly1980’sonmanyturbochargedDieselengines.Itisdifficulttomanufacturechargeaircoolerscompletelyfreeofleaks,andDieselengineperformanceisnotsignificantlyaffectedbyslightchargeairleaks.Consequently,mostenginemanufacturerspublishallowableleakratesforchargeaircoolers.5.TestingTwotypesofleaktestsarecommon:5.1PressureDecay5.1.1PROCEDURECaptheinletandoutletofthechargeaircooler.Oneofthecapsneedstohaveanadapterforasupplyofcompressedair.THECAPSNEEDTOBESECUREDTOTHECHARGEAIRCOOLERWITHCABLESORCHAINSTOPREVENTBLOW-OFFS.Attachashopairlinetotheadapterwithapressuregauge,regulatorandshut-offvalve.Supplyairtothechargeaircoolertothespecifiedmaximumpressure,thenshutoffthevalveandmeasurethetimeforthepressureinthechargeaircoolertodecaytothespecifiedminimumpressure.5.1.2CRITERIAThespecifiedpressuresandtimesareavailablefromthemanufactureroftheengineorchargeaircooler.Typicalvaluesareintherangeofa20-50kPa(3-7psi)pressurelossfrom100-200kPa(15-29psi)gagepressurein15-60seconds.5.2SubmersionTest5.2.1PROCEDURESupplyairperProcedure5.1.1abovewhilethechargeaircoolerissubmergedinwater.Capturetheairbubblesthatleakfromthecoolerandmeasurethevolumeofleakedairduringaspecifiedtimeperiod.Thisprocedureisdifficulttoperforminthefieldandisprimarilyusedatthechargeaircoolermanufacturingfacility.5.2.2CRITERIAThespecifiedleakratesatagivenpressureareavailablefromthemanufactureroftheengineorchargeaircooler.Typicalleakratesareintherangeof10-200cc/min(1-12cubicinches/min)at100kPa(15psi)gagepressure.SAEJ2679IssuedNOV2004-3-6.Notes6.1LeakRateTrendsIngeneral,allowablechargeaircoolerleakratesarebeingreducedbyenginemanufacturersasnewerenginesbecomemoresensitivetochargeairleakage.Thelatestenginespecificationsmustbeutilizedtodetermineup-to-daterequirements.6.2CausesofLeaksAllowablechargeaircoolerleaksaretypicallycausedbyminordefectsinwelding,brazingorcastingprocesses.Theseleakswillnotgetworseovertime.Fatiguecracksinatube,headerortankarenotconsideredallowableleaksandwillresultinhigherleakratesovertimeasthecracksgrow.PREPAREDBYTHESAECOOLINGSYSTEMSSTANDARDSCOMMITTEEOFTHESAEPOWERTRAINSYSTEMSGROUPSAEJ2679IssuedNOV2004RationaleNotapplicable.RelationshipofSAEStandardtoISOStandardNotapplicable.ApplicationThisdocumentisapplicabletoallair-to-airchargeaircoolersusedwithinternalcombustionengines.ReferenceSectionSAEJ1148—EngineChargeAirCoolerNomenclatureSAEJ1542—LaboratoryTestingofVehicleandIndustrialHeatExchangersforThermalCycleDurabilitySAEJ1597—LaboratoryTestingofVehicleandIndustrialHeatExchangersforPressureCycleDurabilitySAEJ1598—LaboratoryTestingofVehicleandIndustrialHeatExchangersforDurabilityunderVibrationInducedLoadingTMCRecommendedPracticeRP331—ChargeAirCoolerIntegrityDevelopedbytheSAECoolingSystemsStandardsCommitteeSponsoredbytheSAEPowertrainSystemsGroup