Case Study #3: Corrosion-Resistant Heat Exchanger for Automotive Test Chamber
Initial situation
In the automotive industry, corrosion test chambers are used to simulate harsh environmental conditions, including temperature swings from -15°C to +60°C (5°F to 140°F) and exposure to salt-laden air. These chambers must be precisely air-conditioned to meet test standards, with fast temperature regulation being critical.
However, traditional stainless steel air heat exchangers are unsuitable for this environment due to the risk of rust particles contaminating the air and test samples. The customer needed a solution that eliminates all corrosion risk.
Challenge
Working alongside the system manufacturer, the objective was to design a corrosion-resistant heat exchanger that could:
-
Deliver rapid heating and cooling in the air inflow duct
-
Operate with a medium temperature range of -30°C to +80°C (-22°F to 176°F)
-
Eliminate any metallic materials susceptible to corrosion
-
Be custom-fitted for the chamber’s air circulation system
Solution
Calorplast engineered a gas-to-liquid heat exchanger made entirely from PE-RT (Polyethylene of Raised Temperature Resistance). This high-performance plastic:
-
Withstands both extreme cold and elevated temperatures
-
Is 100% corrosion-resistant, ideal for salty, corrosive air environments
-
Is constructed as a solid plastic unit—no coatings, no rust risk
-
Was custom-designed in collaboration with the customer to ensure seamless integration and performance
Result
The corrosion test chamber now operates without any risk of metallic contamination, ensuring clean test conditions and stable temperature control. The PE-RT heat exchanger provides long-lasting, maintenance-free performance, even in one of the most demanding environments in the automotive sector.
