Clad Tube vs Conventional Radiators: What OEM Engineers Need to Know

Clad Tube vs Conventional Radiators: What OEM Engineers Need to Know

Introduction

Modern vehicle platforms, from compact cars to off-highway machinery, are pushing the limits of thermal performance. To meet increasing demands for heat rejection, reduced weight, and enhanced durability, OEM engineers must make an informed decision between traditional radiators and those built with advanced clad tube technology.

If you're involved in aluminium radiator design or focused on optimising radiator durability, this comparison is essential reading.

1. Understanding Conventional Radiators

Conventional radiators are typically made using copper-brass or simple aluminium cores with mechanically joined tubes and fins. These systems have served reliably for decades, but they come with some limitations:

  • Higher weight (especially with copper)
  • Mechanical joints are prone to long-term leakage
  • Limited compatibility with modern compact engine bays
  • Less efficient heat transfer at lower surface area-to-volume ratios

While still relevant in many applications, these traditional designs are gradually being replaced where performance or packaging efficiency is a priority.

2. What is a Clad Tube Radiator?

Clad tube radiators are constructed using multi-layer aluminium tubes (clad tubes) that are brazed in a controlled atmosphere furnace. The clad layer melts and bonds all components, such as tubes, fins, and headers, into a single, highly durable core.

Key Characteristics:

  • All-aluminium construction
  • No mechanical joints, resulting in fewer leak points
  • Lightweight and compact
  • Superior corrosion resistance due to aluminium alloys and cladding

3. The Engineering Advantage of Clad Tubes

For engineers working on aluminium radiator design, clad tubes offer measurable technical advantages:

  • Improved Thermal Performance: Thin-wall multiport tubes maximise contact area, improving heat rejection rates, ideal for turbocharged engines and compact cooling modules.
  • High Pressure Endurance: Brazed assemblies maintain integrity under extreme pressures, perfect for heavy-duty and commercial applications.
  • Corrosion Resistance: The external clad layer offers sacrificial protection, significantly extending service life, especially critical in HVAC condensers and intercoolers exposed to harsh environments.
  • Design Flexibility: Clad tubes allow variable thickness, fin density, and flow path optimisation, enabling engineers to fine-tune performance without changing footprint.

4. Durability: A Clear Win for Clad Designs

Durability is where clad tube radiators outperform their conventional counterparts significantly. Since there are no gaskets or solder joints involved, the risk of vibration-related failure drops drastically. This leads to:

  • Fewer warranty claims
  • Reduced service downtime
  • Lower total cost of ownership

For mission-critical applications like mining machines or generator sets, this added resilience is not optional; it's essential.

5. Application-Wise Comparison Table

Feature

Conventional Radiator

Clad Tube Radiator

Material

Copper/Aluminium

All-Aluminium Brazed

Joining Method

Mechanical/Soldered

Brazed (no joints)

Thermal Efficiency

Moderate

High

Corrosion Resistance

Variable

Excellent (with cladding)

Weight

Heavier

Lighter

Durability in Harsh Conditions

Lower

Very High

Customization Options

Limited

High


Why It Matters for OEM Engineers

Whether you're designing for the aftermarket, industrial vehicles, or compact EVs, your choice of radiator directly affects:

  • Cooling system efficiency
  • Packaging constraints
  • Long-term durability
  • Manufacturing repeatability

Engineers who adopt clad tube technology early in the design phase can future-proof their platforms while optimising cost, space, and performance.

Ready to Engineer the Future of Cooling?

At Varun Radiators, we manufacture high-performance all-aluminium radiators using clad tube technology designed for OEM requirements. Our integrated capabilities include:

  • In-house brazing furnace for consistent joint integrity
  • Rapid prototyping and testing for new platform integration
  • Custom design support for every radiator size and orientation

From ICE to EV and off-road platforms, we support engineering teams in creating smarter, stronger cooling systems.

Conclusion

Clad tube radiators aren’t just a design upgrade; they’re a reliability revolution. For OEM engineers aiming to balance performance, weight, and durability, switching to clad technology is a step toward long-term thermal efficiency.

Looking to incorporate clad tube radiators into your next platform?
Let’s collaborate on an optimised, tested, and ready-to-launch solution.

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