Air conditioner failure investigation-intergranular cracking in a pure copper condenser tube

Abstract

A failure of a 7 1/2-year-old commercial rooftop air conditioning system was investigated. The systematic failure analysis procedure and eventual discovery of a leak in a pure copper condenser coil are discussed. Severe denting of several tubes, including the tube that leaked, was discovered in the area of the steel tube sheet. A metallurgical examination, including scanning electron microscopy, revealed intergranular cracking, a process that is common among some copper alloys suffering from stress-corrosion cracking but is rarely observed in pure copper. Research of available literature is presented, and the conditions under which pure copper may exhibit intergranular cracking are discussed. Also presented are vibration measurements of the air conditioner taken during operation, which rule out operating loads as the cause of the tube denting and eventual cracking. The cause of the denting remains unknown. However, the denting probably occurred during manufacturing, and the high stresses associated with the dents, in the presence of corrosion, resulted in intergranular cracking and eventual leaking.