Aluminum for HVAC&R heat exchangers and tubing

Micro-channel heat exchangers 

Hydro supplies multi-port extruded (MPE) tube for brazed micro-channel. Micro-channel tubes have inherent technical advantages that result in the highest thermal performance gains possible. The metallic bond between tube and fin eliminates the contact resistance found in mechanically expanded designs, improving heat transfer efficiency. Combined with the micro-channel tube geometry, this supports a smaller, lighter unit and a significant decrease in refrigerant charge. A lower-depth core can also reduce air-side pressure drop by up to 50% compared with a conventional heat exchanger with the same air-side frontal area.  

Tube and fin heat exchangers

Tube-and-fin remains the most common heat exchanger design in HVAC&R, and Hydro supplies aluminum tube and fin as a direct alternative to traditional copper tube/aluminum fin coils. Pairing aluminum tube with aluminum fin provides better corrosion resistance through improved galvanic coupling than a mixed-metal design while also delivering immunity to formicary corrosion, a failure mode that affects copper tube. Internally enhanced tube options can improve refrigerant-side heat transfer by increasing inner-surface area and can also influence refrigerant flow characteristics.  

Aluminum tubing for line sets 

Hydro aluminum tubing for line sets and connecting lines are made with a special alloy developed specifically for HVAC&R applications. Standard dimensions range from 1/4 inch to 1 inch, and customized dimensions are available on request. An optional polyamide (PA) or polyethylene (PE) coating layer provides additional protection against corrosion and physical damage. Installation guidance covers appropriate tooling, torque values and joining methods.    

Aluminum vs copper in HVAC&R

When comparing copper and aluminum for HVAC&R equipment, six factors matter most: cost, weight, thermal performance, durability, corrosion behaviour and recyclability.

• Cost: Aluminum is typically priced at around one-fourth the price of copper on a per-tonne basis, and application studies have shown bill-of-material savings in the range of 34–48%. Because aluminum heat exchangers contain significantly less material by weight, fluctuations in LME pricing have a much smaller impact on manufacturing costs than with copper-based designs.  
• Weight: As a rule of thumb, an aluminum tube-based heat exchanger weighs only half as much as its copper equivalent. Depending on the design, complete heat exchanger weight can be reduced by 17–34%, while tube weight reductions can reach approximately two-thirds. The lower weight can also reduce handling and logistics costs.  
• Thermal performance: In a tube-and-fin design, the difference in overall heat transfer coefficient between a copper-tube and an aluminum-tube exchanger of identical geometry is negligible at approximately 1%. The fin-to-air interface, rather than the tube wall itself, is the dominant factor governing overall performance.
• Durability: In conventional copper tube/aluminum fin heat exchangers, galvanic interaction between dissimilar metals can contribute to gradual fin degradation over time. An all-aluminum design provides a balanced alloy combination that reduces this corrosion mechanism and helps maintain long-term performance.  
• Corrosion: Aluminum is immune to formicary ("ant-nest") corrosion, a failure mode estimated to account for approximately 10% of premature indoor heat exchanger failures. Aluminum is also compatible with ammonia refrigerant systems, whereas copper cannot be used because of ammonia attacks.
• Recyclability: All-aluminum heat exchangers can be recycled without first separating different materials, unlike mixed-metal designs. This simplifies end-of-life processing and improves material recovery.   

Condenser application	Fin & tube (Cu tube/Al fin)	Fin & tube (Al tube/Al fin)	Micro-channel (Al tube/Al fin)
Required space	100%	100%	28%
Tube weight	100%	33-66%	33%
Heat exchanger weight	100%	66-83%	42%
Tube cost per exchanger	100%	20-40%	30%
Refrigerant charge	100%	100-86%	7%
Lifetime	High fin corrosion	All-aluminum balanced alloy combination	All-aluminum balanced alloy combination
Recyclabilty	Separation needed	No separation needed	No separation needed

How we can support your transition

Switching from copper to aluminum is more than a material change. Success depends on choosing the right alloys, understanding application requirements and implementing proven manufacturing practices. We support customers throughout the transition with specialised materials, technical expertise and decades of HVAC&R experience.

• Proven HVAC&R alloys designed for corrosion resistance, durability and long-term performance.
• Technical expertise to help evaluate designs, applications and manufacturing considerations.
• Workshops and training that provide practical guidance on working with aluminum and adopting best practices across the value chain.
• Proven success built on decades of experience supplying aluminum solutions that have delivered reliable performance in HVAC&R applications worldwide.
• Tools, knowledge and support to help customers minimise risk, avoid common pitfalls and achieve a successful transition.
• A trusted long-term partner with more than 50 years of aluminum extrusion experience, backed by a global technical and manufacturing network.

Explore the possibilities with a complimentary workshop

Considering aluminum for your HVAC&R applications? We offer free technical workshops for manufacturers interested in understanding the opportunities and challenges of transitioning from copper to aluminum.

During the workshop, our specialists can help you:

• Evaluate potential applications and benefits
• Discuss corrosion and durability requirements
• Review alloy and product options
• Share best practices for manufacturing and installation
• Identify key considerations for a successful transition

Whether you are just beginning to explore aluminum or already planning a transition, we can help you build the knowledge and confidence needed to move forward.

Frequently asked questions about copper substitution