Compare & Contrast Aluminum with Copper Brass Construction Radiators
7 Reasons to stock Plastic Aluminum truck radiators
- Fitment- Better fit because plastic tanks mirror the complex OE shapes
- Better cooling
- Brazed aluminum lasts longer and endures more pressure cycles for a longer life
- Lighter in weight
- Strength- plastic tanks have superior design reinforcements that cannot be done in a stamped tank
- Less expensive- materials and methods on a volume basis keep production costs down
- Low warranty return rate- In modern trucks Tier 3 and up, the duty cycles cannot be upheld with copper brass radiator construction
Common radiator metals ranked by thermal conductivity
For the majority of automotive history copper brass radiators have been the used for many reasons including copper being the best conductor of heat. But copper is too weak for other parts of the radiator so an alloy of copper is used, brass (check the chart). In most radiator applications copper is used for the fins transferring a lot of heat which helps but holding all the brass and copper together is a solder alloy which is much lower on the heat transfer rank. Keep in mind that the poor conductor, solder is between all of the good conductive metals, slowing transfer. Solder is the weak link being a soft metal with a low melting point often failing first from metal fatigue(cracking). Also solder traditionally has a lead (Pb) content and it is well known to be a toxic heavy metal.
Only now in recent times has modern chemistry allowed inexpensive manufacturing methods to braze All Aluminum radiator cores. The cores are made up of different aluminum alloys, combining strength and heat transfer properties. Aluminum is a better conductor than brass. In other words, it is 100% aluminum conductor making its construction more efficient than comparable copper brass radiators with dissimilar metals.
| Rank | Metal | Thermal Conductivity [BTU/(hr·ft⋅°F)] |
|---|---|---|
| 1 | Copper | 223 |
| 2 | Aluminum | 118 |
| 3 | Brass | 64 |
Since the very beginning copper and brass radiators have been a staple component of most cooling systems. Today you’ll still find copper and brass radiators in a variety of industries and applications. But as manufacturing designs and technology have improved, “Plastic Tank/Aluminum Core” product have become the original equipment industry standard as a quality replacement to the copper and brass product. In most applications they last longer, they’re lighter, and cost less money!
In the Heavy Duty Truck market, Northern Radiator has offered you a choice of copper/brass as well as a plastic/aluminum radiators to various truck models, and where it makes sense we will continue to do so. However, it’s very apparent that in many specific part numbers, applications, and working environments, Northern’s plastic tank/aluminum radiator is far superior in its performance, longevity and customer satisfaction with substantially fewer warranty situations.
| Aluminum | Copper Brass |
|---|---|
| Stronger metal - more resistant to pressure and damage | Weaker metal |
| Core and headers are brazed as one solid piece, allowing uniform heat transfer - no solder | Core and headers are soldered together, reducing heat transfer capability |
| Wider tubes provide better contact with fins for better heat transfer | Smaller tubes mean less cotact with fins and reduces heat transfer |
| Core is thinner allowing better air flow, wider aluminum tubes provide greater surface contact with the fins, it can conduct heat more efficiently than the copper brass | Core is thicker, which can impede air flow |
| Lower weight, 40-60% lighter- less stress on mounting points | Heavier |
| All aluminum - less risk of corrosion | Composed of dissimilar metals due to the solder, which increases risk of corrosion |
| Less expensive than equivalent copper brass by about half | Up to double the price of aluminum |
| More durable and lasts longer in most environments | Heavier and more vulnerable to vibration and self-destruction in certain applications |
| Most modern trucks are designed for aluminum radiators | Most modern vehicles are not designed for copper brass, increasing the risk of galvanic corrosion |
Northern Plastic Aluminum Products
| PART # | MAKE/MODEL without Frame | OEM # | PART # with Frame |
|---|---|---|---|
| 238601 | Int’l/Navistar ‘03-’07 8600, 8600i, 9100, 9100i, 9200, 9200i, 9400, 9400i, 9900i Series | 2508454C91, 2508454C92, 3E0115430000 | - - - - - - - - |
| 238603 | Freightliner ‘04-’06 Columbia, M2 with Mercedes Engine | BHTD0535, D0535, D9526 | - - - - - - - - |
| 238611 | Freightliner ‘07-Newer Cascadia, Century, Columbia | 3E01228, 1A0201190021, 0529617009 | 238684, 238709 |
| 238612 | Freightliner ‘08-’13 M2, ‘08-’10 Cascadia, Sterling 9500 Series | 1A0201220032, 052661922, 0527751066 | - - - - - - - - |
| 238617 | Freightliner ‘04-’07 M2 Bus with Mercedes Engine | BHT91657, BHTD2342, D2342 | - - - - - - - - |
| 238632 | Freightliner 07-’09 Cascadia | 0526678001, 0526621001 | - - - - - - - - |
| 238638 | Kenworth ‘06-’11 T660, ‘08-’15 W900, 2014 T880 | N4020001, F3160881101120, F3160881105100 | - - - - - - - - |
| 238648 | Peterbilt ‘08-’13 384 & 386; Kenworth ‘08-’14 W900 | F3160921214310, M3265001, BHTH4102, H4102 | - - - - - - - - |
| 238652 | Freightliner ‘08-Newer Columbia with PTO, Sterling LT 9500 | 1A0201220012, 3E0120460001, 3E11548 | 238746 |
| 238695 | Int’l/Navistar ‘04-Newer 7300-7700 Series | 286042C91, 2586039C91, 2507375C91 | - - - - - - - - |
| 238697 | Int’l/Navistar ‘02-’07 7300-7700 Series | 2586038C91, 1S180075, 2508431C91 | - - - - - - - - |
| 238698 | Int’l/Navistar ‘08-’09 7300, 7400, 7500 Series | 2591761C92, 1S180186, 3E113970000 | - - - - - - - - |
| 238759 | Ford ‘94-’97 and ‘01-Newer L, LTL9000, Sterling, Silver Star, Freightliner 1300 | F4HT8009FC, F4HT8009FB, 1040145 | - - - - - - - - |
| 239010 | Freightliner ‘03-’10 Century Series, Coronado B5325, C8989, 75080, | BHTC8987 | - - - - - - - - |
| 239048 | Mack ‘08 CHU Series, ‘08-’13CHN Series, GU Granite E Models, Volvo ‘08-’14 VHD Series | 21504550, 85125540, 21593033 | - - - - - - - - |
| 239050 | Mack ‘08-’10 Granite, Volvo VHD Series | S5751, S5589, Y8075, 85112703, 21504540 | - - - - - - - - |
| 239077 | Freightliner ‘06-’09 M2, MC, MM Models | B9705, B9696, D9454, BHT74683 | - - - - - - - - |
| 239086 | Freightliner ‘07 Columbia, ‘08-Newer Cascadia | 1A0201190020, 3E0118600004, A0526615020 | 238685 |
| 239087 | Freightliner ‘08-’13 M2 / 106 Business Class, ‘08-’09 Sterling Acterra | BHTT3152001, T3152001, S2726001, P4022001 | - - - - - - - - |
| 239089 | Volvo ‘06-’08 VT, V2 Models | 20517559, G5713, G5719, G0440100 | - - - - - - - - |
| 239123 | Mack CX, CXN61; Volvo ‘97-Newer VN, VNL, VNM Models | 8113190, 81493, 3MF5544M4, 3100801 | 239141, 239154 |
| 239142 | Freightliner ‘02-’07 FLD, Century, Classic XL, Sterling 9500 Series | BHTA4727, V0225001, E3760, V0225100 | - - - - - - - - |