TL 874
Issue 2010-06
Class. No.:8LF70
Descriptors:
radiator, cooling system, temperature
Radiator
Functional Requirements
Previous issues
TL 874: 1973-11, 1996-10, 1998-12, 2006-02Changes
The following changes have been made as compared to TL 874: 2006-02:–Standard completely revised
–Requirements expanded to include pressure pulse resistance–Temperature cycle test incorporatedContents
Page
1Scope .........................................................................................................................22Description .................................................................................................................23General requirements ................................................................................................23.1As-received condition .................................................................................................23.2Materials .....................................................................................................................23.3Operating temperature ...............................................................................................23.4Mandatory technical engineering approval (BMG) .....................................................24Radiator testing ..........................................................................................................34.1Cooling performance ..................................................................................................34.2Pressure drop .............................................................................................................34.3Leak tightness under pressure ...................................................................................34.3.1Vacuum ......................................................................................................................34.3.2Over-pressure ............................................................................................................44.4
Pressure pulse resistance for quality assurance and technical engineering
approval .....................................................................................................................4
Check standard for current issue prior to usage.
This electronically generated standard is authentic and valid without signature.
Page 1 of 11
The English translation is believed to be accurate. In case of discrepancies the German version shall govern.Numerical notation acc. to ISO practice.Technical responsibilityStandards DepartmentEAFPGünther ArensTel.: +49 5361 9 26158EKDV/4 Wolfgang TiefenbachEKDVEGDB/2Manfred ReuschelTel.: +49 5361 9 77196Tel.: +49 5361 9 75357Manfred TerlindenConfidential. All rights reserved. No part of this document may be transmitted or reproduced without prior permission of a Standards Department of the Volkswagen Group.Parties to a contract can only obtain this standard via the B2B supplier platform www.vwgroupsupply.com.
© Volkswagen Aktiengesellschaft
VWNORM-2008-12m
SILON :ELLEUQPage 2
TL 874: 2010-06
4.54.64.74.84.94.104.10.14.10.251
Vibration resistance ....................................................................................................5Vibration resistance with temperature load ................................................................5Static temperature and pressure loading ...................................................................6Corrosion of DUT .......................................................................................................6Low-temperature test .................................................................................................7Temperature cycle test ...............................................................................................7Single-flow radiator ....................................................................................................8Dual-flow radiator .......................................................................................................9Referenced documents ............................................................................................10Scope
This Technical Supply Specification (TL) contains the tests necessary for series-production releaseof radiators. The objective is complete testing carried out at the sole responsibility of the supplier.This standard applies to mechanically joined and soldered radiators for passenger cars and com‐mercial vehicles with water-cooled engines.2
Description
Functional requirements acc. to TL 874
3
General requirements
Approval of first supply and changes according to Volkswagen standard VW 01155.The environmental requirements set forth in VW 91100 must be met.
The test equipment required for carrying out the procedures in this TL must be located directly at theproduction site. Alternative test methods are only permissible if correlation with the tests specifiedherein has been proven and this has been agreed upon with the purchaser.Original couplings and fasteners (e.g., spring clamps) must be used for the tests.
The following applies to the coolant additive according to TL 774 required in this standard: the additiveapproved by Volkswagen at the time of the test must be used.3.1
As-received condition
Free of impurities (on the inside and on the outside). Ports and openings must be protected so thatsoiling and damage during storage, transport, and installation are excluded.3.2
Materials
Materials according to the drawing.3.3
Operating temperature
(-40 to +135) °C
Operating temperature range3.4
Mandatory technical engineering approval (BMG)
The requirements according to Section 4 must be met for the mandatory technical engineering ap‐proval.
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TL 874: 2010-06
4 Radiator testing
A total of 20 radiators must be configured in all possible variants from at least two batches of reser‐voirs, pipes, and fins and must undergo measurements for cooling performance and pressure drops.The measured values must be reported to the engineering department. All radiators must meet therequirements for cooling performance and pressure drop set forth in the Performance Specifications.4.1
Cooling performance
The operating points for the cooling performance measurement and the limits for the performancedata of the radiator must be obtained from the vehicle-specific Radiator Performance Specificationsor the drawing.
The following must be submitted to the relevant engineering department for purposes of determiningthe cooling performance:
One component with average cooling performanceOne component with minimum cooling performance4.2
Pressure drop
The operating points for the pressure drop measurements and the limits for the permissible pressuredrops of the radiators must be obtained from the vehicle-specific Radiator Performance Specificationsor the drawing.
The following must be submitted to the relevant engineering department for purposes of determiningthe pressure drops:
One component with average cooling air pressure dropOne component with maximum cooling air pressure dropOne component with average coolant pressure dropOne component with maximum coolant pressure drop4.3
Leak tightness under pressure
100% testing at the supplier's facilities.
The method used for the leak tightness test may be chosen by the supplier.Coolant must not escape from the radiator under any vehicle operating conditions.4.3.1
Vacuum
Air
(23 ± 5) °C
≤ 30 mbar absolute5 s
Test mediumTest temperatureTest pressure
Hold time after reaching the test pressureCriterion for leak tightness
Maximum pressure rise within the hold time1 mbar
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TL 874: 2010-06
4.3.2 Over-pressure
Air
(23 ± 5) °C
2,5 bar over-pressure, drawing note takes precedence5 s
Test mediumTest temperatureTest pressure
Hold time after reaching the test pressureCriterion for leak tightness
No air bubbles rising from radiator to which the test pressure is applied and that is held under water.4.4
Pressure pulse resistance for quality assurance and technical engineering approval
The requirements according to Section 4.3 must be met prior to the tests. Unless otherwise specified,the following test criteria apply:Test procedure:
Test medium
Medium temperature
Test chamber temperaturePressure pulse frequencyPressure pulse rangePminPmax
Number of DUTs
Minimum number of load cycles (LC) foreach radiator i
Number of load cycles for terminationCriterion for process reliability Formula for average value:
(1)
100% coolant additive acc. to TL 774(135 - 5) °C1)(85 ± 5) °C
(0,5 to 1) Hz (sinusoidal)2)
(1,25 ± 1,15) bar over-pressure 1)0,1 bar over-pressure2,4 bar over-pressure12 new partsN ≥ 100 000250 000 LC ≥100 000 LC
Formula for logarithmic standard deviation:
(2)
Criterion for process reliability:
(3)
N = Number of load cycles upon failure of radiator i, or upon reaching the number of cycles for ter‐mination. One period of the sinusoidal pressure pulse is designated as one load cycle (LC).After testing, the DUTs used must meet the functional requirements according to Section 4.3.2.
1)2)
Measured at the inlet port
Permissible test range for system-specific reasons
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TL 874: 2010-06
4.5 Vibration resistance
The part to be tested must be mounted on the test bed in as-installed position with the designatedfasteners; if available, it must be fitted with all released add-on parts in the front end; it must be filledcompletely with a mixture of 50% coolant additive according to TL 774 and 50% water.
The center of the top of the radiator must be chosen as the measuring point for the acceleration.Number of DUTsDirection of vibration
Acceleration of the test part at ± 2,5 gAcceleration of the test part at ± 5 gVibration frequency
2 new partsVertical
Number of load cyclesn = 10 × 106Number of load cyclesn > 2 × 106
Constant at (20 ± 3) Hz (add-on parts not resonant)
For decoupled radiators, the test amplitudes must be based on the vehicle measurement values (ifavailable).
After the test, the components must be leak-tight according to Section 4.3.2.4.6
Vibration resistance with temperature load
This test applies only to mechanically joined radiators.
The part to be tested must be mounted on the test bed in as-installed position with the designatedfasteners; if available, it must be fitted with all released add-on parts in the front end; it must be filledcompletely with a mixture of 50% coolant additive according to TL 774 and 50% water.
The center of the top of the radiator must be chosen as the measuring point for the acceleration.Number of DUTs
Test chamber temperatureVibration accelerationNumber of cyclesVibration frequency
≥ 3 new parts≥ 60 °C± 2,5 gn ≥ 107
Constant at (20 ± 3) Hz (add-on parts not resonant)
For decoupled radiators, the test amplitudes must be based on the vehicle measurement values (ifavailable).
After the test, the components must be leak-tight according to Section 4.3.2.
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TL 874: 2010-06
4.7 Static temperature and pressure loading
The devices under test (DUT) may be subjected to flow, if necessary to ensure a constant tempera‐ture. The maximum flow rate per DUT must be agreed with the relevant engineering department priorto starting the test and must be documented using examples.An erosion within the DUT caused by flow is not permitted.Number of DUTsTemperatureSystem pressureTest mediumTest duration
4 new parts(135 - 5) °C
2 bar over-pressure
Mixture of 60% coolant additive according to TL 774 and40% water800 h
After every 170 h, cool down to room temperature (23 ±5) °C for 1 h, and then check for leak tightness accordingto Section 4.3.2
Afterwards, the DUTs undergo a pressure pulse test to determine the residual resistance. This testis performed according to Section 4.4, but with a number of cycles for termination of 60 000 LC.Release criterion: Minimum number of load cycles for all radiators of 30 000 LC.After the test, the components must be leak-tight according to Section 4.3.2.4.8
Corrosion of DUT
Climate corrosion cycle test for 24 weeks according to Test Specification PV 1209Number of DUTs
≥ 5 new parts
After the test, the requirements of PV 1209, Sections \"Leak tightness test\" and \"Microsections\" mustbe met.
For mechanically joined radiators with steel pipe bottoms, the external corrosion test must be per‐formed for 1 200 h according to DIN EN ISO 9227.Number of DUTs
≥5
Following the test, the components must be leak-tight according to Section 4.3.2.
Corrosion (e.g., surface damage such as pitting, blooming) is permissible only at the points that aredefined on the drawing as unprotected for manufacturing reasons.
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TL 874: 2010-06
4.9 Low-temperature test
≥2 new parts
Number of DUTs
In order for the seal to set, the radiators are aged at an ambient temperature of 130 °C for a periodof 24 h. The radiators must be filled with a mixture of 50% coolant additive according to TL 774 and50% water during this aging. To ensure a pressure build-up during the aging at 130 °C, the radiatorsmust be tightly sealed.
Afterwards, the radiators are aged at a temperature of -40 °C for a period of 8 h.
Immediately following removal of the radiators from the cold chamber, the test according toSection 4.3.2 is performed with the following modified values:Test pressure
Pressure hold timeLeakage is not permitted.4.10
Temperature cycle test
1,2 bar over-pressure5 min
The temperature cycle test is regarded as a technical engineering release test only when carried outin consultation with the engineering department.
Thermographic images of the radiator in the vehicle must be recorded in order to identify large tem‐perature differences and to perform the test based on the most critical case. The test setup and testprocedure are then specified in consultation with the responsible engineering department.Recording of operational loads
The loads on the radiator are recorded using strain gages and temperature sensors at the criticalpoints of the radiator network during driving on the design-relevant courses of Volkswagen AG andAudi AG.
The measurements must be performed at ambient temperatures that allow the critical loads to occurmost often.
Load spectrums are determined from the strain amplitudes. For the temperature cycle tests on thetest bed, the engineering department (EGDB or other) will provide a minimum stress-cycle diagram(mean value line) computed from these load spectrums, which will serve as the basis for evaluatingthe tests.
Test bed setup for the radiators
Cyclical flow through the air conditioning condenser and the radiator. Use of a series productionelectric fan, equipped with series production fan mounting frame, that is actuated only during thecooling phase. For the positions of the temperature measuring points, see Figure 1 for single-flowradiators and Figure 2 for dual-flow radiators.
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TL 874: 2010-06
4.10.1 Single-flow radiator
Positions of the temperature measuring points T1 to T3.
Figure 1 – Single-flow radiator
LegendT 1T 2T 3
Measuring point 1, inlet temperatureMeasuring point 2
Measuring point 3, outlet tempera‐ture
WKR
Reservoir
Radiator networkPipe bottom
Position of the strain gages (1 to 8):
On the face of the first and last pipes in the area of the pipe/pipe bottom, at both the inlet and outletends.
Test conditions:
Test chamber temperatureInlet temperatureFlow rateTest medium
Static internal pressure (p)Changeover criteria–
Stop inflow of heated coolantTemperature T2
Tupper = (83 ± 3) °CP = 80%
Tlower = (-1 ± 3) °CΔT = 84 °C
(-10 ± 3) °C(130 ± 3) °C8 l/min
100% coolant additive according to TL 774(1 ± 0,1) bar over-pressure
Cool down with fan power–
Start new cycle after cooling-downTemperature T2
Double amplitude1.
The number of load cycles required will be specified based on vehicle measurements.
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TL 874: 2010-06
2.
For this purpose, temperature values for the control temperature point T2 are assigned to thestrains based on a calibration on the test bed. The minimum stress-cycle diagram must becomplied with.Number of DUTs4 new parts
If the vehicle measurements did not identify any strains, the following requirement applies:Number of DUTs4 new partsAverage number of cycles until failure ≥8 000 LCStandard deviation
Slog ≤ 0,2
Number of load cycles for terminationn = 12 000 LC
4.10.2 Dual-flow radiator
Positions of the temperature measuring points (T1 to T6).
Figure 2 – Dual-flow radiator
Legend
T1 and T4Measuring points for the inlet tem‐
perature
T2 and T5Position of measuring points T2 and
T5: 20 mm from the pipe bottom,center of the upper radiator network,bottom of the upper pipe
T3 and T6Measuring points for the outlet tem‐
perature
HTHigh-temperature radiatorPosition of the strain gages (1 to 16)
On the face of the first and last pipes in the area of the pipe/pipe bottom, at both the inlet and outletends, on both the high-temperature and low-temperature radiator.
NTWKR
Low-temperature radiatorReservoir
Radiator networkPipe bottom
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TL 874: 2010-06
The timing of the inflow of the heated coolant must be the same for the high- and low-temperatureradiators in each cycle.
For test conditions for the high-temperature radiator (HT), see Section 4.10.1Test conditions for the low-temperature radiator (NT):Test chamber temperatureInlet temperatureFlow rate
Test medium
Static internal pressure (p)
Changeover criteria–
Stop inflow of heated coolantTemperature T5
Tupper = (50 ± 3) °CP = 80%
Tlower = (-1 ± 3) °CΔT = 51 ℃
(-10 ± 3) °C(70 ± 3) °C
To be chosen based on temperatures Tupper and Tlower100% coolant additive according to TL 774(1 ± 0,1) bar over-pressure
Cool down with fan power–
Start new cycle after cooling-downTemperature T5
Double amplitude1.
2.
The number of load cycles required will be specified based on vehicle measurements.
For this purpose, temperature values for the control temperature point T5 are assigned to thestrains based on a calibration on the test bed. The minimum stress-cycle diagram must be com‐plied with.
Number of DUTs4 new parts
If the vehicle measurements did not identify any strains, the following requirement applies:Number of DUTs4 new partsAverage number of cycles until failure ≥8 000 LCStandard deviation
Slog ≤ 0,2
Number of load cycles for terminationn = 12 000 LC
5 Referenced documents
The following documents cited in this standard are necessary for application.
In this Section terminological inconsistencies may occur as the original titles are used.
Standards with the titles given in German are either only available in German or may be procured inother languages from the institution issuing the standard.PV 1209TL 774VW 01155
Condensers, Radiators and Charge Air Coolers made of AL Alloy; Corro‐sion Test (Climate Corrosion Cycle Test)
Ethylene Glycol-Based Coolant Additive; Material RequirementsVehicle Supply Parts; Approval of First Supply and Changes
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TL 874: 2010-06
VW 91100DIN EN ISO 9227
Environmental Standard for Vehicles; Vehicle Parts, Materials, OperatingFluids; Policy, Specifications
Corrosion tests in artificial atmospheres - Salt spray tests
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