Hydro supplies tubing for all-aluminum suction and liquid line sets for HVAC&R systems, engineered as a direct alternative to copper. Switching to aluminum lowers weight and reduces exposure to copper price volatility environments.
Hydro's aluminum tubings are manufactured using alloys developed specifically for HVAC&R applications. For line set applications, Hydro has designed 9048 and 9159 alloys for high corrosion resistance precision drawn tubes. 3003 alloy is also available.
Aluminum is roughly a third the density of copper, with the adjustment of the wall thickness to meet the pressure requirement, the aluminum tubing is less than half the weight of copper tube for the same length providing a significant weight advantage and helping to reduce handling and transportation weight. The cost of a tube consists of both the material cost and the fabrication cost. While the fabrication cost of aluminum tube is higher per kilogram than the cost of fabricating copper tube, the fabrication cost per metre is lower due to the substantial difference in density. In addition, fluctuations in raw material prices have less impact on the manufacturing cost of aluminum heat exchangers than copper alternatives.
It is estimated that 10% of indoor heat exchangers fail prematurely due to formicary corrosion, a corrosion mechanism that has motivated HVAC&R manufacturers to transition away from copper in certain applications. Aluminum is immune to formicary corrosion and can be used without restrictions when exposed to formicary acid, unlike copper. This corrosion advantage applies not only to line sets, but also wherever aluminum replaces copper elsewhere in the system, including in fin and tube heat exchangers and micro-channel heat exchangers.
Hydro offers additional protection against corrosion and physical damage with a polyethylene (PE) or polyamide (PA) coating layer. Hydro's HYCOT™ coating technology applies a polyamide and/or polyethylene layer to the tube surface, providing enhanced protection against corrosion and physical attack. In line set applications, HYCOT™ tubing achieves the highest level of robustness on the market.
Standard dimensions and customised dimensions are available.
| Size | Outer diameter |
| 1/4" | 6.36 mm |
| 5/16" | 7.94 mm |
| 3/8" | 9.52 mm |
| 1/2" | 12.70 mm |
| 5/8" | 15.87 mm |
| 3/4" | 19.05 mm |
| 7/8" | 22.23 mm |
| 1" | 25.4 mm |
| Custom | Available on request |
Aluminum line sets differ from copper and must be installed with care. Hydro's installation guidelines highlight several important practices to ensure long-term performance:
Use tools dedicated to aluminum whenever possible. If tools have previously been used with copper, ensure they are thoroughly cleaned before use.
Use a mandrel for swaging aluminum tubes. Do not use an expander.
Protect connections between aluminum and dissimilar metals with a heat-shrink sleeve to help prevent galvanic corrosion.
Apply lower torque when tightening threaded connections, as aluminum is softer than copper.
Store aluminum separately from other metals and keep it dry to avoid contamination and corrosion risks.
Avoid exposure to conditions known to promote corrosion, including environments with a pH below 4 or above.
A line set is the pair of insulated copper or aluminum tubes - a suction line and a liquid line – that carry refrigerant between the indoor and outdoor units of an air-conditioning or refrigeration system. Hydro line sets tubing is available for all-aluminum suction and liquid lines for HVAC&R applications.
Aluminum offers a significant weight advantage compared with copper due to its lower density. Aluminum is also immune to formicary corrosion, and fluctuations in raw material prices have less impact on manufacturing costs than with copper-based alternatives.
No.
Yes. Aluminum-to-copper connections can be made using approved joining methods such as brazing, flare connections or mechanical connections such as INOAC Conic Joint or Lokring®. Connections between aluminum and copper should be protected with a heat-shrink sleeve to minimise the risk of galvanic corrosion. See our installation guidelines for details.
Standard outer diameters from 1/4″ (6.36 mm) to 1″ (25.4 mm), with custom dimensions available on request.
