A radiator is essential for maintaining the optimal temperature of your car's engine. As the engine operates, it generates heat, and without an effective cooling system, this heat can cause the engine to overheat, leading to potential damage or failure. The radiator absorbs excess heat from the engine coolant and dissipates it into the air, keeping the engine within a safe operating temperature range. This prevents overheating, improves engine efficiency, and extends the lifespan of critical components, making the radiator a vital part of any vehicle's performance and longevity.

At Alloyworks, we aim to deliver top-quality radiators that ensure superior performance and longevity. Each radiator undergoes meticulous craftsmanship and advanced engineering. Here’s an inside look at the step-by-step process of manufacturing our car radiators:

Preparation:

Selecting Premium Materials

The process begins with sourcing AA5052 aircraft-grade aluminum, known for its exceptional strength, lightweight properties, and corrosion resistance, even in harsh environments like saltwater exposure. This material ensures the durability and efficiency of our radiators.

Designing the Radiator

Our engineers use cutting-edge design software to create radiator models tailored for optimal cooling performance. The designs account for tube spacing, fin density, and coolant capacity to maximize heat dissipation.

With 3D modeling technology, our engineers are able to intuitively observe and adjust the design, ensuring that the radiator's dimensions, as well as inlet/outlet positioning, and other details are more precise and meet the specific size requirements of the corresponding vehicle model, guaranteeing easy installation.

Production:

1. Cutting and Shaping Aluminum Components

The aluminum sheets are precision-cut using CNC（Computer Numerical Control）machines to create core parts such as tubes, fins, and tanks. CNC machining ensures high accuracy, allowing for seamless assembly and performance reliability.

We use high-powered lasers to cut through sheets of aluminum with precision. It’s ideal for intricate designs and thinner components like radiator water tanks, brackets, and mounting plates.

Precise, custom-shaped components that are ready for further assembly or use in a larger structure.

These parts will undergo further processes like bending, welding, and assembly, ultimately resulting in a fully functional, high-performance aluminum radiator.

2. Making of the radiator outer cases

2.1 Making of the header

The small pieces of aluminum sheets are cut to the designed length for the radiator header and then sent to the punching machine to make the holes for the radiator tubes later on.

 Below are the finished radiator headers:

3. Making of the water chamber

3.1 Water Chamber Shaping

Another pre-cut aluminum sheet will be sent to the hydraulic press for stamping and shaping. With the hydraulic press, a large volume of parts needs to be shaped quickly.

In this step, we use a hydraulic press to press the pre-cut aluminum sheets into specific shapes to create tanks.

3.2 Water Chamber Welding

We are using techniques like TIG (Tungsten Inert Gas) welding to ensure precision and strength in the joints. This welding process ensures a tight, leak-proof seal, allowing the water chamber to withstand high pressure and temperatures while maintaining efficient coolant flow.

Finished water chambers for later assembly.

4. Making of the radiator fins and tubes

4.1 Making of the radiator fins

Aluminum sheets used for radiator fins will be pre-punched with small holes, and then fed into a machine that stamps or presses the material into a series of thin, uniform fins.

Our staff will then collect the fins from the other side of the machine for later assembly.

4.2 Making of the radiator tubes:

A tube mill is a machine used to manufacture metal tubes and pipes through a continuous process.

To make the radiator tubes, an aluminum billet （Aircraft-grade AA5052 aluminum）will be sent to the tube mill, then passes through a series of forming rollers that progressively bend it into a cylindrical or tubular shape.

Once the metal strip is formed into a tube shape, the edges are joined using high-frequency welding (HFW). The edges are heated using electromagnetic induction, and pressure is applied to weld them together, creating a strong, continuous seam.

After welding, the tube passes through sizing rolls to ensure the correct diameter, roundness, and thickness. Adjustments can be made for precision at this stage.

The continuous tube is cut to the desired lengths using an automatic cutting mechanism, ensuring accuracy for specific applications.

5. Assemble of header, fins, and tubes

Headers, tubes, fins, and water chambers will be placed into the assembling station.

We incorporate high-density cooling fins (14-16 fins per inch), which increase the surface area, enhancing the radiator’s ability to transfer heat.

These fins are strategically placed between the tubes to create a denser core that throws off more heat, making our radiators up to 45% more efficient than stock models.

The header then is positioned to secure the fins and tubes in place, and we use a wooden hammer to carefully tighten them together.

6. TIG Welding

After the header, fins, and tubes are assembled, the semi-finished radiator will be sent to the welding process.

6.1 Welding for the water chamber and the radiator cores

Our experienced welders use TIG (Tungsten Inert Gas) welding to assemble the radiator's tanks, fittings, and other structural elements. TIG welding provides a stronger and more precise weld compared to conventional methods, ensuring leak-proof performance.

The welding machine specificc design to weld water chamber and radiator cores together.

Below is the finished product after welding for the water chamber and the radiator cores.

6.2 Welding for water chamber and inlet, outlet, and accessories.

Below is the finished product after welding.

7. Finished product air tightness test 

After welding, every radiator will be rigorously tested for pressure and leak resistance This involves simulating real-world operating conditions to ensure the radiator can handle the demands of high-performance and racing applications.

We use 100% pure water for leakage detection by introducing 0.125 MPa of dry air into the inner cavity, ensuring no leakage occurs within 1 minute.

Radiators that pass the airtightness test are sent to a dryer for high-temperature drying.

8. Making of Radiator Shroud & Fans

8.1 Making of the radiator shrouds

We use a CNC punch press to cut thicker aluminum sheets. The CNC machine is programmed with precise dimensions and cutting paths. The press then applies force to punch through the aluminum, creating clean, accurate cuts for radiator shrouds or similar components.

Pick out the components from the aluminum sheet after punching and press cutting.

8.2 Shroud and fan assemble

Our staff is screwing the fan onto the shroud to ensure the fan is securely and tightly attached.

The photo below is the finished shroud & fans.

9. The final Touches

9.1 Fin straightening:

We use tools such as metal pick to fix or straighten the fins to ensure that the radiator fins are properly aligned and free from bends or dents that could obstruct airflow or heat dissipation.

9.2 Radiator polishing

In this step, we remove unsightly weld marks and water stains, optimizing the product's appearance.

The final product:

10. The packaging

Every radiator is securely packaged with protective forms to prevent damage during shipping.

Accessories such as the thermostat relay kit are packed in a separate bag, which will also be included in the box.

Sealed with sealing tape, the radiator is then nicely and safely packed and ready for shipment.

In Alloyworks, radiators are manufactured using high-quality aluminum, which is both lightweight and highly efficient at heat dissipation. Our precision craftsmanship ensures each radiator is designed for maximum airflow and cooling capacity.

Choosing Alloyworks Radiators means investing in a product that delivers superior performance, durability, and long-term reliability, making it the go-to choice for enthusiasts and professionals alike.