Académique Documents
Professionnel Documents
Culture Documents
14
Guidelines
GEOMETRY CONSIDERATIONS
15
Symmetry
Uniform wall thickness
Large radii
Tongue ratio reduction
Incorporating useful features
ID Mark, drill points, screw slots, location/registration stops
GEOMETRY OPTIMIZATION
16
Convert hollows to solid profile
HEAT SINK RATIO
17
Fin height to gap ratio is typically limited to 16:1.
DAMAGED DIE
18
ALUMINUM USED IN COOLING SOLUTIONS
19
Aluminum heat sinks and liquid coolers have been widely used as
cooling components in power electronics, LED lighting, computers,
telecom devices, healthcare, automotive, etc.
ALUMINUM EXTRUSIONS
20
Recyclable & Non-toxic
Lightweight
Strong
Corrosion resistant
Thermally conductive
Reflective
Electrically conductive
Non-magnetic
Non-sparking
Material Advantages
Attractive
Finish Options
Virtually Seamless
Complex integral shapes
Easily assembled
Weldable
Machinable
Cost-effective
Short lead times
Process Advantages
THERMAL CONDUCTIVITY
21
Copper (pure):
395 W/mK
EXTRUSION ALLOY VS. DIE-CAST ALLOY
22
PROFILE DESIGN
23
PROFILE DESIGN
24
PROFILE DESIGN
25
PROFILE DESIGN
26
PROFILE DESIGN
27
PROFILE DESIGN
28
SURFACE FINISHING
29
Surface Treatment
Emissivity
As extruded 0.10
Clear anodize 0.78
Black anodize 0.85
White paint 0.90
Black paint 0.97
SIMULATION
30
SIMULATION
31
Critical items needed for design support:
Max junction temp (Tj) or thermal resistivity requirements
Ambient temperature and boundary conditions
Heat sink orientation relative to gravity
Heat load definition and placement (Watts)
CAD assembly detailing heat sink and mating components with
material definitions (SolidWorks or .stp file)
Re-design space limitations / requirements
FRICTION STIR WELDING
32
Friction Stir Welding is a solid-state joining method, which has been used
in the welding of aluminum since 1991.
METHOD
33
WELD STRUCTURE
34
Fully re-crystallized fine grain micro-structure is created in the nugget by
the intense plastic deformation at elevated temperature.
ADVANTAGES OF FRICTION STIR WELDING
35
No filler metal (parent metal conductivity)
High tensile, fatigue, and bend properties
Void free and leak proof
Low thermal distortion and shrinkage
Energy efficient
Suitable for automation
Cost Effective
FSW MODULAR HEAT SINK*
36
*PATENT PENDING
FSW HEAT SINK VS. BONDED FIN HEAT SINK
37
FSW Bonded
METALLOGRAPHIC EXAMINATION
38
THERMAL TESTING SETUP
39
THERMAL RESISTANCE
40
The thermal resistance of FSW modular heat sink is 8% lower than
bonded fin design.
*THE DEFINITION OF THERMAL RESISTANCE:
EXTRUDED FSW LIQUID COOLER*
41
*PATENTED BY SAPA
METHOD
42
The liquid cooler is sealed by friction stir welding the lids to the extruded
body.
METALLOGRAPHIC EXAMINATION
43
PRESSURE TEST
44
The liquid cooler can withstand burst pressure up to 90 bar.
THERMAL TEST SETUP
45
Double-sided mounting with 1500 Watt per side
THERMAL RESISTANCE
46
PRESSURE DROP
47
SUMMARY
48
Thermal
Performance
- Alloy selection
- Fin design/spacing
- Heat sink
orientation
- Surface treatment
- CFD Analysis
Extrusion Design
- Weight reduction
- Profile
functionality
- Space limitations
- Best practice
manufacturing
Efficient cost
effective
solution
CONTACT
49
Alex Chen, PhD
Sr. Application Engineer
Sapa Extrusions Americas
Alex.Chen@sapagroup.com
801-450-7221
Angel Rosario
Sr. Application Engineer
Sapa Extrusions Americas
Angel.Rosario@sapagroup.com
847-349-7244
Mike Tozier
Technology Development Mgr.
Sapa Extrusions Americas
Mike.Tozier@sapagroup.com
503-802-3462
Questions?
Paul Heney
Design World
pheney@wtwhmedia.com
Phone: 440-234-4531
Twitter: @DW_Editor
Mike Tozier
Sapa Extrusions Americas
Mike.Tozier@sapagroup.com
Phone: 503-802-3462
Alex Chen, PhD
Sapa Extrusions Americas
Alex.Chen@sapagroup.com
Phone: 801-450-7221
Angel Rosario
Sapa Extrusions Americas
Angel.Rosario@sapagroup.com
Phone: 847-349-7244
Thank You
This webinar will be available at
designworldonline.com & email
Tweet with hashtag #DWwebinar
Connect with Design World
Discuss this on EngineeringExchange.com