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The evaporator coil is made of copper tubing ran through aluminum fins. The whole assembly is held together by support plates called header plates made of stainless steel. Although stainless steel, it still rusts and corrodes which in turn makes jagged edges where the copper tubing passes. These jagged edges eat into the copper tubing and cause pinhole leaks or worse and are for the most part non repairable, or at least not cost effective to repair. Sometimes you will have a fitting leak that was not welded properly or a heavy contact point that rubbed through, both of which are repairable if accessible. But by far a leaking header plate is most often the culprit. Thicker copper tubing from the manufacture process would help but if anyone would bring back the all aluminum coil we could see the end of leaks. Guess why they don't make them anymore...

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15y ago

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