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In this paper, the results of experimental and numerical studies on joining the thin fins to the thick base plate of a heat exchanger are presented. The elements of the heat exchanger were joined by using developed method of press forming. The joining technology consists in clamping the sheet metal into the channel of the base plate using a punch with specific geometry. The effect of different configurations of the punch geometry (shape, radius and distance between fin and punch) and the indentation depth on the depth of the interface between the fin and base plate is analysed. Furthermore, the effect of different combinations of fin-base plate materials has been numerically studied. The plate material was the AA2219 -T851 aluminium alloy, while the fins were made of the AA5251 aluminium alloy. The elastic-plastic numerical computations of the joining process have been carried out using the finite element-based MSC.Marc program. It was found that the area of the contact of the fin with the base plate can be optimised by choosing the right parameters of the tool geometry and technological parameters. Experimental research has shown that increasing the punch indentation causes the material to flow in the transverse direction to the punch and the indirect extrusion in the region between the punches.

Effect of Pressing Parameters on the Quality of Joint Formation of Heat Exchanger Fins with the Base Plate