Welding introduces contact resistances in the joint between pipe and external horizontal fin. Any other better methods to join the fin with the pipe? Say Copper fin with copper pipe (or) mild steel fin with mild steel pipe.
I'm assuming that you are talking about a heat exchanger. Typically, the fins would be brazed on. A full penetration weld will also eliminate any contact resistance.
One way of getting good connection is by shrink fitting - if your application permits. It also introduces some thermal resistance, but you are not limited to using the same material for the pipe and the fin(s). Remember that different materials has different thermal expansion coefficients and may loosen when your heat exchanger heats up.
You can try and find extrusions that has the fin(s) integrated into the tubing, e.g. aluminium extrusions.
Thanks a lot for all for your inputs - I will go for Brazing - If I want to make in bulk (or) require many finned tubes which other methods of forming is good?
Apart from brazing, adhesives for bonding metals may also be an option ... (one of the advantages being that they do not cause distortion, discoloration, or weld worms that may require secondary operations such as grinding or painting). Fins and parental part should appropriately be configured for this.
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