Modern high-efficiency heat exchangers used in renewable energy systems are more and more often based on light metals and their alloys. The reasons for this are both economic and technical. Aluminium alloys show very good properties e.g. low mass density and heat conductivity and the price of the material is advantageous compared to any alternative compounds. The analysed group of heat exchangers is utilized in new generation of compact hybrid solar panels used for cogeneration of electrical energy and heat from sun radiation. The heat exchanger properties are determined by the materials of construction, as well as physical properties, technology and erosion and corrosion susceptibility caused by the exchanger’s fluid.The operating parameters of heat exchangers are limited to a great extent by the internal surface condition of the exchanger’s pipes. Their morphology is highly dependent on the manufacturing processes. This paper presents the study on stress and strain obtained from the finite element analysis for aluminium pipes at different stages of their pressure forming.Keywords: aluminium alloys, hybrid solar collector, heat exchanger, FEA method, pressure forming
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