FQB10603 – MATERIAL SCIENCE
REPORT ABOUT
LECTURER: TS. JUNITA BINTI MOHD SAID
NO NAME ID COURSE
1. MUHAMMAD AMIN HAIKAL BIN 50225125297 BAET
MOHAMMAD NIZAM
2. THAQIF HADI BIN ROSMIN 50225125465 BAET
CONTENTS
CONTENTS PAGE
INTRODUCTION
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Conclusion
References
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INTRODUCTION
The overall efficiency and operational longevity of any refrigeration or air-
conditioning unit depend on a seamless mechanical cycle where specialized
components work in perfect synchronization to transfer thermal energy. Central
to this intricate network is the copper tubing, which functions as the system's
primary plumbing. It is specifically engineered from high-grade copper not only
for its superior thermal conductivity but also for its remarkable ductility and
resistance to corrosion, allowing it to contain high-pressure refrigerants over
long periods without risking structural fatigue or leaks. This refrigerant fluid
travels through the network to the heat exchanger, a critical interface designed
to facilitate the rapid swap of thermal energy between the internal chemical
agent and the external environment. By maximizing surface area through
complex fin designs, the heat exchanger ensures that the transition between
liquid and gas phases is as energy-efficient as possible, which is the
cornerstone of the cooling process.
To ensure the system remains both safe and acoustically dampened, the
compressor casing provides a heavy-duty, hermetically sealed protective shell
for the motor. Often referred to as the "heart" of the unit, the compressor is
subjected to intense internal pressures and mechanical vibration; therefore, the
casing serves as a vital shield against environmental wear while simultaneously
acting as a sound barrier to minimize operational noise. Finally, the cooling
coil serves as the functional interface for the end-user, acting as the point
where indoor air is stripped of its latent heat and excess moisture. As warm air
passes over these chilled coils, the temperature drops and the air is
dehumidified, resulting in the crisp, cooled environment we feel. Each of these
components is technically indispensable; a failure in the material integrity of the
tubing or a breach in the compressor casing would immediately halt the entire
thermal cycle, underscoring the vital importance of high-quality engineering in
modern climate control systems.
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MATERIAL IDENTIFICATION
Component Material Material category
1.
Deoxidized High Phosphorus Non-ferrous metal
(DHP) Copper
Copper tubing
2.
Aluminum (Fins) and Copper Non-ferrous metal
(Tubes)
Heat exchanger
3.
Low Carbon Steel or Cast Ferrous metal
Iron
Compressor casing
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Copper (Tubing) with Non-ferrous metal
Aluminum (Fins)
Cooling coil
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MATERIAL PROPERTIES
1. Copper tubing
The most important characteristic for refrigerant lines is good thermal
conductivity. The "gold standard" in this situation is copper since it permits heat
to pass through the tube walls nearly instantaneously. The cooling process
would be extremely slow and waste a lot of electricity if we utilized a material
with weak conductivity. Copper's resistance to corrosion is another reason we
utilize it. The pipes won't thin out or leak with time because it doesn't react
readily with moisture or refrigerants. Additionally, because of its ductility,
professionals can easily flare and bend the pipes without them splitting during
installation.
2. Heat exchanger
The heat exchanger must have good thermal conductivity and be
lightweight, much like the condenser in the outdoor unit. Since aluminum is
significantly lighter than copper or steel, aluminum fins are used in the majority
of designs. This is crucial because outdoor units are frequently installed on wall
brackets; an excessively hefty heat exchanger would overstress the structure of
the building. Aluminum fins provide a large surface area for heat escape while
maintaining the unit's ease of handling and installation.
3. Compressor casing
The compressor casing is primarily concerned with structural strength, in
contrast to the other components. This part serves as a pressure vessel for
high-pressure gas up to 400 psi at times. It must therefore have a high tensile
strength to avoid any chance of rupturing or exploding. For this, we typically
employ cast iron or carbon steel. In order to prevent the shell from developing
fatigue fractures after years of usage, the casing must also have a particular
degree of hardness and toughness to reduce the continuous vibrations and
noise emanating from the internal motor.
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4. Cooling coil
The cooling coil, also known as the evaporator, is nearly always wet
since it is continuously exposed to moisture. Corrosion resistance is therefore
of utmost importance. Refrigerant could escape through "pinhole" leaks caused
by rust or oxidation of the metal. The coil remains intact when non-ferrous
metals, such as copper or suitably coated aluminum, are used. It needs
excellent thermal conductivity, just as the tubing, to extract heat from the room
air as quickly as the fan sweeps it across the fins.
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Engineering Application & Analysis
1. Corrosion
Corrosion is the process where a material, especially metal, slowly deteriorates
due to chemical reactions with the surrounding environment such as air,
moisture, or chemicals. In refrigeration and air-conditioning systems, corrosion
usually occurs when metal components are exposed to humidity, water
condensation, or certain refrigerants.
For example, copper pipes and aluminum fins are commonly used because they
have good resistance to corrosion. However, if a low-quality material such as
untreated steel is used, rust can easily form on the surface of the pipe. Over time,
this rust can weaken the material and create small holes or leaks in the refrigerant
pipes.
Corrosion can reduce the efficiency of the air-conditioning system because
refrigerant may leak out of the system. When refrigerant levels drop, the system
cannot absorb heat effectively, causing poor cooling performance. In severe
cases, corrosion can lead to complete system failure and require expensive
repairs or replacement of parts.
Therefore, selecting corrosion-resistant materials is very important in
refrigeration engineering to ensure long-term durability and reliable system
performance.
2. Fracture
Fracture refers to the cracking or breaking of a material when it is subjected to
excessive stress, pressure, or repeated mechanical forces. In refrigeration and air-
conditioning systems, many components operate under high pressure and
constant vibration, especially inside the compressor and refrigerant pipes.
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If the material used is not strong enough, it may develop cracks over time. For
example, the compressor housing must be made from strong materials such as
steel because it needs to withstand high internal pressure and mechanical forces
during operation. If a weaker material is used, it may break or crack, causing
refrigerant leakage or compressor failure.
Fractures can also occur due to fatigue, which happens when a material
experiences repeated stress over a long period of time. Small cracks may
gradually grow until the component eventually breaks.
A fractured component can be dangerous because it may suddenly fail during
operation. This can damage other parts of the system and reduce the overall
reliability of the refrigeration system. Therefore, engineers must carefully select
materials with high strength and durability to prevent fracture.
3. Overheating
Overheating occurs when the temperature of a component rises beyond its safe
operating limit. In refrigeration and air-conditioning systems, overheating can
happen if materials cannot transfer heat efficiently.
For instance, components such as condensers and evaporators rely on materials
with high thermal conductivity to transfer heat quickly. Copper and aluminum
are commonly used because they allow heat to move easily through the material.
If a material with poor heat conductivity is used, heat will not be released
effectively from the system.
When heat builds up inside the system, the compressor may have to work harder
to maintain the desired temperature. This can lead to higher energy consumption
and increased wear on the compressor. In extreme cases, overheating can cause
insulation damage, compressor burnout, or system shutdown.
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Therefore, using materials that can effectively conduct and dissipate heat is
essential for maintaining efficient and safe operation of refrigeration and air-
conditioning systems.
4. Deformation
Deformation refers to the change in shape or size of a material when it is exposed
to stress, pressure, or high temperatures. In refrigeration and air-conditioning
systems, certain components must maintain their shape in order to function
properly.
For example, condenser and evaporator fins are designed to have a specific
structure that maximizes airflow and heat transfer. If the material used is too soft
or weak, it may bend or deform due to heat, air pressure, or physical impact
during operation.
Deformation can reduce the efficiency of heat exchange because bent fins or
pipes may restrict airflow or refrigerant flow. This can cause uneven cooling and
reduce the overall performance of the air-conditioning system.
In addition, deformation can also lead to misalignment of components, which
may create vibrations or mechanical stress in other parts of the system. Over
time, this may shorten the lifespan of the equipment.
Therefore, materials used in refrigeration systems must have sufficient strength
and thermal stability to maintain their shape under operating conditions.
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REFERENCES
1) [Link]
conditioners/how-do-air-conditioners-work/
2) [Link]
3) [Link]
4) [Link]
your-refrigeration-system
5)
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