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OEM Truck Maker Is First to Use Brazed Copper-Brass URAL Installs Cuprobraze Radiator-And-CAC Package in World-Class Trucks

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OEM Truck Maker Is First to Use Brazed Copper-Brass URAL Installs Cuprobraze Radiator-And-CAC Package in World-Class Trucks CuproBraze® 36 EXECUTIVEReport OEM Truck Maker Is First to Use Brazed Copper-Brass URAL Installs CuproBraze Radiator-and-CAC Package in World-Class Trucks oday,URAL is unrivaled in currently meet the Euro II regulations; mean- the design and manufacture while,URAL management is looking forward to of rugged 4 × 4,6 × 6 and 8 × meeting the next stages of lower emissions stan- 8 truck models.As a leading dards.New engines and cooling systems are manufacturer of off-road being developed for highway and off-road trucks in Russia,it enjoys a trucks to meet these new requirements as well. market share of more than 70 According to Alexander Vedernikov,Technical percent for full-drive trucks; Development Manager,URAL engineers envision and 20 percent of that coun- all future designs of URAL trucks with CuproBraze Ttry’s total truck market.Additionally,URAL advanced heat exchanger technology. exports about 25 percent of its production,and it plans to enter the heavy-duty on-highway Passability, Reliability, Versatility truck market as well. High passability is a trademark of URAL trucks and a part of the company’s heritage.“Passability” First OEM to Adopt CuproBraze could be defined in terms of the truck or the URAL passed many milestones in recent years terrain.Given Russia’s vast territories and harsh on its way to becoming a world-class truck climate,the production of off-road trucks that maker.One important achievement this year can drive though extremely rough terrain is cru- was becoming the first OEM truck maker in the cial to its economy.With powerful engines and world to use CuproBraze® radiators.It now uses special driving axles,URAL trucks are engi- CuproBraze products made by SHAAZ in all of neered to withstand the most challenging off- its trucks. road conditions imaginable. For example,they Advanced CuproBraze designs replace sol- can operate in 1 meter (3.3 ft) deep untrodden dered copper-brass radiators,which has allowed snow,or 1.7 meter (5.6 ft) deep water; and they URAL to skip over intermediate aluminum tech- can drive over 1.3 meter (3.9 ft) ditches and nologies.By adopting the most advanced heat 0.55 meter (1.8 ft) vertical walls. exchanger technology available today,well in URAL trucks are essential to huge Russian advance of other off-road truck makers around industries such as oil,forestry and agriculture. the globe,URAL has shown that it is a leader Some of the most sought-after features of these rather than a follower. trucks are high load-capacity,superior reliability Besides using CuproBraze brazed copper- and repairability — not to mention versatility: brass radiators in all new models of its trucks, URAL truck chassis serve as platforms for nearly approximately 95 percent of its trucks have 180 different types of vehicles,including buses, CuproBraze charge air coolers as well.In fact, cranes,fuel tankers and heavy wreckers. many URAL trucks are installed with an integral Taking into account the above,it is not sur- heat exchanger that includes a radiator and prising that URAL trucks are counted among charge-air-cooler in one package.This approach the toughest and most durable in the world. simplifies production and assembly processes. Comparable ruggedness and durability is All new models of URAL trucks now URAL trucks are equipped with the diesel demanded of every subsystem,especially the have CuproBraze brazed copper-brass engines produced by Yaroslav Motor Plant cooling system.The truck radiators and charge radiators, and nearly all have (YaMZ).These 180- to 400-horsepower engines air coolers must be durable to an extreme. CuproBraze charge air coolers. EXECUTIVEReport URAL trucks are mounted with powerful CuproBraze heat-exchangers are ready for URAL is the first OEM truck maker to adopt diesel engines from Yaroslav and cooling mounting in URAL trucks. SHAAZ integrates CuproBraze technology. This advanced new systems from SHAAZ. the charge air cooler and radiator into a sin- technology simplifies the development of gle package before delivery to URAL. The clean diesel engines that meet stringent new integrated package can be quickly and easily emissions standards. mounted into the engine compartment at the URAL plant. The Road to Modernization tors and charge air coolers for many Russian URAL’s plant is located in the city of Miass,in over-the-road and off-road truck makers. the Urals region,which is considered to be the “After our specialists attended several semi- industrial heart of Russia.The plant encompass- nars and visited SHAAZ’s new plant,it was obvi- es a fully automated assembly line that can pro- ous that CuproBraze was exactly what we need- duce 30,000 trucks per year.With the coopera- ed,”says Alexander Vedernikov,Manager of tion of Western partners,URAL recently renovat- Technical Development at URAL.“We were so ed the facility’s painting,tooling and calibration interested in CuproBraze that we made a finan- departments.The plant now is certified accord- cial investment in SHAAZ to help them begin ing to key criteria (ISO 9000 standards) of the production as soon as possible.” International Organization for Standardization, “It was a special advantage for us,”notes qualifying it to supply parts to the global auto- Vedernikov,“when SHAAZ began to supply motive marketplace. packages that integrated the radiators with the Today,all URAL trucks incorporate charge air coolers.This approach simplifies our CuproBraze radiators,and 95 percent of the assembly process and saves time.” company’s trucks tout CuproBraze charge-air coolers.These numbers include the 3,000 vehi- Durability — Defined cles per year manufactured by IVECO-URALAZ, “In Russia,we do not traditionally install alu- URAL’s joint-stock company with IVECO,a lead- minum radiators on trucks,”Vedernikov says. ing international manufacturer of heavy-duty “The majority of our trucks have been equipped trucks,parts and diesel engines.SHAAZ-made with soldered copper-brass radiators.” CuproBraze radiators cool the 370-horsepower CuproBraze technology is a method of IVECO 8210.42.k diesel engines on board URAL- joining new alloys of copper and brass with a IVECO 6329 trucks. filler metal that melts at a relatively high For 2004,the company expects to turn out brazing temperature.The CuproBraze alloys 19,000 vehicles,all of which will be equipped and brazing process result in joints that are with CuproBraze copper-brass radiators manu- much stronger than soldered joints.This Internationally renowned IVECO-URAL advanced technology was developed to man- 6329 trucks now benefit from factured by its main supplier,SHAAZ. CuproBraze technology. ufacture a new generation of exceedingly A Beneficial Relationship durable automotive, heavy-duty truck and SHAAZ previously opened a high-volume pro- industrial heat exchangers. duction facility in Shadrinsk,Russia [Ref.1] and “The CuproBraze process produces strong, since then has been brazing copper-brass radia- lightweight,compact and efficient heat exchangers,”says Vedernikov.“The prototype complex heat exchangers than in radiator that we first examined was 25 percent the past.The high temperature per- more efficient than conventional radiators. formance of copper-brass charge More important,brazed copper-brass serpentine air coolers allows them to retain fins are more durable than their alternatives. much of their strength and avoid Reliability is a crucial advantage in Russia, metal corrosion.By replacing tem- because service stations can be several thou- perature-challenged aluminum sand kilometers apart.For the same reason, charge air coolers with copper- reparability is also important.CuproBraze is a brass counterparts,the automotive natural fit for URAL.” industry can reduce emissions and Vedernikov further explained that URAL increase fuel efficiency. trucks need to operate at ambient temperatures ranging from 55 degrees below zero to 122 Glorious Past, Promising above zero on the Fahrenheit scale (i.e.,from Future –50 °C to +50 °C).The cooling systems also URAL was founded under the name need to be forgiving to the quality of coolants. URALAZ in 1944 when it began Drivers cannot afford to deal with frequent fail- making trucks for the Russian army. URAL truck with 4 x 4 wheel drive ures of cooling systems; and,when there is a Many of these trucks were mounted with the descends a steep incline. leak in a cooling system,it is essential to make now famous “Katyushas,”which were the first repairs in the field. mobile rocket or missile launchers to be used Because they are made of brass rather than in World War II [Ref.2].URAL trucks today are aluminum,CuproBraze charge air coolers and the progeny of these famous military trucks, radiators can withstand the higher operating which played such a decisive role in ending the pressures and temperatures associated with war and upon which the company first staked new designs of diesel engines.Due to stringent its reputation. international emissions standards,and stricter This year marks its sixtieth anniversary,and Russian standards scheduled for 2005,URAL URAL is celebrating not only its conspicuous engineers are confident that CuproBraze is the service in the past eras but also its spectacular right choice for the future.Tougher standards modern-day achievements and beckoning mean clean diesel engines will require more future.The toughness and passability of today’s URAL truck with 8 x 8 wheel drive com- petes in truck trials, passing over rugged terrain (left), preparing to descend a steep incline (top) and approaching the bottom of the hill (bottom). The International Copper Association, Ltd. (ICA) is the leading organization for the promotion of the use of copper worldwide. The Association’s twenty-nine members represent about 80 percent of the world’s refined copper output, and its six associate members are among the world’s largest copper and copper alloy fabricators.
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