PowerPoint Presentation

Aluminum extrusion design and the role it plays in high performance cooling solutionsThis webinar will be available afterwards at www.designworldonline.com & email

Q&A at the end of the presentation

Hashtag for this webinar: #DWwebinarBefore We StartModeratorPresentersPaul HeneyDesign WorldMike TozierSapa Extrusions AmericasAlex Chen, PhDSapa Extrusions AmericasAngel RosarioSapa Extrusions Americas

Aluminum extrusion design and the role it plays in high performance cooling solutionsAngel Rosario, Alex Chen, Mike Tozier4

outline5Introduction of Sapa GroupAluminum Extrusion DesignThermal Design ConsiderationsHigh Performance Cooling Solutions

Sapa group6Sapa is the world leader in aluminum solutions a new company thatjoined 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 americas7Sapa Extrusions North America offers design, manufacturing, fabrication and finishing of aluminum extrusions through 25 facilities located across North America.

Profile design8What 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 factorsDie BreakageAlloyProfile type and circle sizeNon-fill conditionThin walls or sharp cornersThick to Thin Ratio (variable bearings)Tolerance requirements

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Product design cost factorsType of ProfileSolidSemi-HollowHollowAlloy / Temper6063 vs. 6061Wall Thickness Thin? Thin to Thick?

TolerancesStandard AA vs. TighterCut LengthLong Lengths vs. Short LengthsSurface FinishAnodize? Paint?

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Profile classificationsSolidLow production costLow die costSemi-HollowTooling could break soonerHigher material and die costHollowHigher Material and Tooling CostMulti-Void hollows have the highest cost

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Circle size diameter12

Profile circle sizeNot 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.

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Minimum wall thicknessRecommended 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.

4567891011320.1880.0780.0940.1250.0700.0620.0560.0500.0520.0560.0620.0700.0780.0930.1000.1250.14214Guidelines

Geometry Considerations15Symmetry

Uniform wall thickness Large radiiTongue ratio reductionIncorporating useful featuresID Mark, drill points, screw slots, location/registration stops

Geometry optimization16

Convert hollows to solid profile

Heat sink Ratio17Fin height to gap ratio is typically limited to 16:1.

Damaged die18

Aluminum used in cooling solutions 19Aluminum heat sinks and liquid coolers have been widely used as cooling components in power electronics, LED lighting, computers, telecom devices, healthcare, automotive, etc.

Aluminum extrusions20

Recyclable & Non-toxicLightweightStrongCorrosion resistantThermally conductiveReflectiveElectrically conductiveNon-magneticNon-sparking

Material AdvantagesAttractiveFinish OptionsVirtually SeamlessComplex integral shapesEasily assembledWeldableMachinableCost-effectiveShort lead times

Process AdvantagesThermal conductivity21

Copper (pure): 395 W/mK Extrusion alloy vs. die-cast alloy22

Profile design23

Profile design24

Profile design25

Profile design26

Profile design27

Profile design28

Surface finishing29Surface TreatmentEmissivityAs extruded0.10Clear anodize0.78Black anodize0.85White paint0.90Black paint0.97

simulation30

simulation31 Critical items needed for design support:Max junction temp (Tj) or thermal resistivity requirementsAmbient temperature and boundary conditionsHeat sink orientation relative to gravityHeat 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 welding32Friction Stir Welding is a solid-state joining method, which has been used in the welding of aluminum since 1991.

Method33

Weld structure34Fully re-crystallized fine grain micro-structure is created in the nugget by the intense plastic deformation at elevated temperature.

Advantages of friction stir welding35No filler metal (parent metal conductivity)High tensile, fatigue, and bend propertiesVoid free and leak proofLow thermal distortion and shrinkageEnergy efficientSuitable for automationCost Effective

Fsw modular heat sink*36

*Patent pending

Fsw heat sink vs. bonded fin heat sink37

FSWBonded

Metallographic examination

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Thermal testing setup

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Thermal resistance40The 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

method42The liquid cooler is sealed by friction stir welding the lids to the extruded body.

Metallographic examination43

pressure test44The liquid cooler can withstand burst pressure up to 90 bar.

Thermal test setup45Double-sided mounting with 1500 Watt per side

Thermal resistance46

Pressure drop47

summary48

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

contact49Alex Chen, PhDSr. Application EngineerSapa Extrusions AmericasAlex.Chen@sapagroup.com801-450-7221

Angel RosarioSr. Application EngineerSapa Extrusions AmericasAngel.Rosario@sapagroup.com847-349-7244

Mike TozierTechnology Development Mgr.Sapa Extrusions AmericasMike.Tozier@sapagroup.com503-802-3462

Questions?Paul HeneyDesign Worldpheney@wtwhmedia.comPhone: 440-234-4531Twitter: @DW_EditorMike TozierSapa Extrusions AmericasMike.Tozier@sapagroup.com Phone: 503-802-3462Alex Chen, PhDSapa Extrusions AmericasAlex.Chen@sapagroup.com Phone: 801-450-7221Angel RosarioSapa Extrusions AmericasAngel.Rosario@sapagroup.com Phone: 847-349-7244Thank YouThis webinar will be available at designworldonline.com & emailTweet with hashtag #DWwebinarConnect with Design WorldDiscuss this on EngineeringExchange.com