Incomplete braze joints have been found inside the customer’s cooling plates. The joints in question are limited to the intersection where the two core plates meet the fitting. These incomplete joints have resulted in leak sites during module assembly after having passed a cooler production leak test. X-Rays of many parts have shown braze joint lengths which range from completely filled (ideal) to having 2 mm or less of the joint filled. The customer has expressed that the fittings can be bent during assembly. The case study examines the potential consequences if they bend these fittings. The force applied has been estimated as 27N at a distance of 36mm from the fitting-plate edge interface, corresponding to a bending moment of about 1Nm.

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