At KAK, we design and manufacture professional-grade copper headers and stainless steel & copper composite header assemblies engineered for uniform fluid distribution and collection. Utilizing high-purity seamless copper and premium stainless steel (SS304/SS316L), our header components are widely specified for commercial, residential, and industrial HVAC/R heat exchangers, ensuring maximum heat transfer efficiency, structural integrity, and long-term leak-proof reliability.
Key Advantages of KAK Header Assemblies
- Versatile Material Options: Available in 100% TP2 (C12200) pure copper for maximum thermal conductivity, or innovative Stainless Steel Main Body + Copper Branch combinations for superior mechanical strength, corrosion resistance, and cost efficiency.
- Advanced Forming Technologies: We offer high-precision extrusion and collar forming methods for branched outlets: Friction Drilling (T-Drilling) for a completely chipless, ultra-clean interior, and Automated Mechanical Punching & Flanging for deep-drawn collars that maximize contact area for brazing.
- Atmosphere Furnace & Automated Brazing: Utilizing state-of-the-art continuous mesh-belt atmosphere brazing furnaces, we execute flux-free, oxidation-free joining between copper branches and stainless steel/copper headers. This guarantees high-strength, pristine joints with zero internal scaling or micro-leakage.
- High-Pressure Capability: Engineered specifically to handle high-stress applications, including sub-critical and trans-critical CO2 (R744) systems and modern eco-refrigerants, with working pressures up to 45 bar (or customizable for ultra-high-pressure requirements).
- Custom Engineering & Cleanliness: Fully customizable pipe lengths, outer diameters (OD), wall thicknesses (up to 2.0mm+), and branch counts as per your Technical Purchase Specifications (TPS). Internally deburred and thoroughly washed to eliminate contamination and oil trapping.
Technical Specifications
| Technical Parameter | Standard Options & Capabilities |
|---|---|
| Main Pipe Material Options | TP2 / C12200 Deoxidized Copper OR SS304 / SS316L Stainless Steel |
| Branch Pipe Material | TP2 / C12200 Seamless Copper Tube |
| Main Body OD Range | Ø12.7mm up to Ø76mm (or fully customized sizes for large manifolds) |
| Branch Forming Process | Friction Drilling (T-Drill Chipless Process) / CNC Collaring & Flanging |
| Joining Process | Continuous Mesh Belt Controlled Atmosphere Furnace Brazing / Automated Induction Brazing |
| Working Pressure Rating | Standard 30 bar to 45 bar (Higher pressure ratings available upon request) |
Our custom manifold headers are the ideal choice for high-end HVAC original equipment manufacturers (OEMs), chiller builders, and engineering contractors seeking reliable fluid control solutions for advanced heat pumps, dry coolers, VRF systems, and commercial refrigeration units.
Frequently Asked Questions (FAQ)
Q1: When should I choose a Stainless Steel + Copper Header over a Pure Copper Header?
Stainless steel + copper composite headers are highly recommended for large-diameter main pipes, high-operating-pressure systems (such as CO2 / R744 refrigerant loops), or aggressive environments where external/internal corrosion resistance is vital. They offer superior structural rigidity at large sizes, prevent pipe sagging, and provide significant cost savings compared to heavy, large-diameter copper pipes—while maintaining easy copper-to-copper brazing at the branch ends for installation.
Q2: How do you guarantee the quality of the joint between Stainless Steel and Copper?
Joining dissimilar metals requires precise thermal control. We utilize continuous mesh-belt protective atmosphere furnace brazing with specialized silver-based filler metals. The inert/reducing atmosphere prevents oxidation without needing corrosive fluxes, ensuring a clean interior and a silver-bright, metallurgically bonded joint that withstands extreme pressure fluctuations and thermal shock.
Q3: What is the difference between your T-Drilling and Mechanical Punching options?
Our Friction Drilling (T-Drilling) process uses thermal friction to soften the pipe metal and form a collar without creating any metal cuttings, guaranteeing 100% internal cleanliness to protect compressors. Our Mechanical Punching & Flanging process utilizes precise automated tooling to pull out deep, rigid collars, which provides a highly stable mechanical fit and superior capillary support for high-volume OEM productions.
Q4: What leak detection procedures do your header manifolds undergo?
Quality is our top priority. Every single custom header assembly undergoes rigorous factory pneumatic pressure hold tests and high-sensitivity underwater bubble leak detection (or optional helium leak testing). We ensure that every brazed joint achieves 100% airtightness before the products are packaged and shipped globally.
Q5: Do you accept production based on customized blueprints or OEM designs?
Absolutely. KAK specializes in custom OEM manufacturing. You can provide your CAD engineering drawings detailing the exact material specifications, branch spacing, hole sizes, and connection tail lengths. Our engineering team will review your parameters to offer an accurate commercial proposal and tiered volume pricing.
