Aluminum Extrusion Design And The Role It Plays In High Performance Cooling Solutions

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Engineering

Published on April 8, 2014

Author: DesignWorldOnline

Source: slideshare.net

Aluminum extrusion design and the role it plays in high performance cooling solutions

 This webinar will be available afterwards at www.designworldonline.com & email  Q&A at the end of the presentation  Hashtag for this webinar: #DWwebinar Before We Start

Moderator Presenters Paul Heney Design World Mike Tozier Sapa Extrusions Americas Alex Chen, PhD Sapa Extrusions Americas Angel Rosario Sapa Extrusions Americas

ALUMINUM EXTRUSION DESIGN AND THE ROLE IT PLAYS IN HIGH PERFORMANCE COOLING SOLUTIONS ANGEL ROSARIO, ALEX CHEN, MIKE TOZIER 4

OUTLINE 5 Introduction of Sapa Group Aluminum Extrusion Design Thermal Design Considerations High Performance Cooling Solutions

SAPA GROUP 6 Sapa is the world leader in aluminum solutions – a new company that joined the aluminum extrusion businesses of Sapa and Hydro. Together, we are shaping a lighter future through a global reach and local presence within extrusions, building systems, and precision tubing. We have 23,000 employees in more than 40 countries, and our headquarters are located in Oslo, Norway.

SAPA EXTRUSIONS AMERICAS 7 Sapa Extrusions North America offers design, manufacturing, fabrication and finishing of aluminum extrusions through 25 facilities located across North America.

PROFILE DESIGN 8 What is the goal? Design the optimal profile that fulfills the demands of the application at the lowest possible cost. To design the optimal profile, we must understand factors in production that increase costs.

TOOLING COST FACTORS Die Breakage Alloy Profile type and circle size Non-fill condition Thin walls or sharp corners Thick to Thin Ratio (variable bearings) Tolerance requirements 9

PRODUCT DESIGN COST FACTORS Type of Profile Solid Semi-Hollow Hollow Alloy / Temper 6063 vs. 6061 Wall Thickness Thin? Thin to Thick? Tolerances Standard AA vs. Tighter Cut Length Long Lengths vs. Short Lengths Surface Finish Anodize? Paint? 10

PROFILE CLASSIFICATIONS Solid Low production cost Low die cost Semi-Hollow Tooling could break sooner Higher material and die cost Hollow Higher Material and Tooling Cost Multi-Void hollows have the highest cost 11

CIRCLE SIZE DIAMETER 12

PROFILE CIRCLE SIZE Not all presses with the same container size are alike. For example, Sapa has a number of 10” presses, but profiles that fit one 10” press may not fit another 10” press at a different location. Circle size is one of the factors for determining the appropriate size press a given profile. Sapa is able to extrude profiles with circle sizes up to 22” in North America. 13

MINIMUM WALL THICKNESS Recommended minimum wall thickness for 6063 Alloy are shown in the guidelines. (Add 15% for 6061 Alloy) Sapa also offers specialty extrusions up to 5” diameter circle size with wall thickness as thin as 0.015” and as light as 0.007 pounds per foot. 4” 5” 6” 7” 8” 9” 10” 11” 3” 2” 0.052” 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

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