Right Manufacturing Solution for Aluminum Heat Sink
Despite being small, the heat sink serves a very critical role in appliances. For instance, computers tend to build up a lot of heat during use. The heat sink in the CPU functions to cool it and thereby extend the computer’s lifespan. We can also find a heat sink in the tube of a TV set where the power supply is light. Aluminum is an excellent material option when choosing to make a heat sink. Here is an extensive insight into how we at Creatingway, help you pick the right manufacturing solution for an aluminum heat sink.
Material Selection for Heat Sink
There is an array of material options for the heat sink. One can choose to make it using silver, aluminum, copper, and steel. The different materials differently influence the intended heat dissipation effect of the heat sink. Silver emerges as the best from thermal conductivity analysis. It is, however, not the material of choice owing to the being quite costly. The second best option falls to aluminum and it ends up being our favorite material. Regardless of the cost or thermal conductivity, it emerges as the most inclusive material. Simply put, it is cheap and light.
Principle of the Aluminum Heat Sink
The aluminum heat sink works via a rather simple mechanism. It has a large surface area and therefore quicker heat dissipation. It thus plays offers a good heat transfer effect owing to its quick heat absorption and heat loss.
Common Manufacturing Options for the Aluminum Heat Sink
Extrusion of Aluminum Heat Sink
The extrusion process is ideal for the mass creation of the aluminum heat sink. This is since it takes little to invest, has a low production cost, and a short development cycle. Aluminum 6063 is the perfect aluminum grade for the extrusion process. The working principle involves heating the aluminum block to between 520-540 degrees Celsius under high pressure. We then allow the molten aluminum liquid to flow through the extrusion mold with grooves. This enables us to create the heat sink embryo. Afterward, we cut the heat sink embryo, the profile grove, and any other processing that makes up the heat sink. Unfortunately, making the heat sink using extrusion has its cons.
There is a certain range in which the fin thickness and length ratio must lie. We refer to this as the pin-fin ratio. It makes up one of the main standards for testing aluminum extrusion tech. The greater the ratio, the greater the effective cooling area of the heat sink. It is, however, difficult to improve the heat dissipation area within the cramped space. Therefore, the heat dissipation effect of aluminum extrusion is not so ideal. We mainly use the aluminum extrusion process in heat sink processing to make columnar or lamellar fins.
Machined Aluminum Heat Sink
Aluminum machining entails an array of processes. A few of them include drilling, milling, turning, and grinding. We can flexibly apply this process depending on the structure of the part. Its use also depends on the function of the structural part like heat sink grooving, plate forming, and bottom surface dressing. Its major con is the relatively fast tool wear and the need for human involvement in machine management. This takes a certain amount of labor cost.
Die Casting of the Aluminum Heat Sink
The principle of aluminum heat sink die casting is quite similar to injection molding. We first heat the aluminum alloy into a liquid at high pressure. Depending on the model, the die casting machine starts to work by cooling and solidifying the molten metal into the desired shape. We can integrate this process into a dense, thin, or complex fin design. Its major con is that it affects the conduction effect and mechanical features of the material. It also limits the nuclear thermal conductivity.
What Are the Common Surface Finish Options for Aluminum Heat Sink?
Sandblasting greatly impacts the surface of the heat sink under high pressure. It is excellent for the removal of dirt and knife lines from the surface of machined aluminum heat sinks. We also use it to make parts look shinier and uniform. This improves the part’s mechanical features and lowers the incidence of fatigue on the heat sink surface.
Brushed surface treatment imparts a more metallic finish and makes it more fashionably sensible. Apart from the aesthetic role, it also increases the heating area of parts to a certain extent. This serves to promote the use efficiency of the aluminum heat sink.
Anodization is one of the most common surface treatment methods in use today. We impart a layer of protective film onto the surface of the part using this method. This not only makes it scratch resistance, but it also ends up wear-resistant. The protective function serves to overcome the surface hardness of aluminum alloy defects.
Electroplating is another protective and aesthetic process we can perform on aluminum heat sinks. It improves the reflection, wear resistance, and electrical conductivity of the parts. At Creatingway, we hope to support your custom designs and needs. Contact us now if you have any inquiries.
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