Stress Characteristics Analysis of Aluminum Brazed Structures (ABS) in Liquid Oxygen Subcoolers Under Liquid Nitrogen Conditions

The liquid oxygen subcooler is a key unit for the deep cooling, storage, and transportation of liquid oxygen. Its frequent start–stop operation under liquid nitrogen bath conditions introduces potential risks to service reliability. This study employs a thermo-structural sequential coupling approach to evaluate the stress behavior of ABS components in a flat plate-fin heat exchanger during the pre-cooling, heat-exchange, and recovery stages. Based on the maximum shear stress (Tresca) criterion, the evolution of principal stresses in the brazed layer under liquid nitrogen bath conditions was analyzed, and a conservative assessment of the material’s fatigue behavior was conducted. The results indicate that the equivalent stress is governed by the third principal stress, originating from the thermal compression effect induced by low-temperature constraint shrinkage. During the heat exchange phase (2700 s), the inlet equivalent stress reached 93.49 MPa, which is below the 258 MPa limit, falling within Region 1. Local stress concentration is primarily driven by thermal loading, with brazing layer thickness, curvature radius, and liquid oxygen pressure serving as key control variables. Under a safety factor of 1.15 (107 MPa), fatigue testing exceeding 1.5 million cycles has confirmed the static safety and operational reliability of the ABS.