Aluminum Extrusion Design And The Role It Plays In High Performance Cooling Solutions
Aluminum extrusion design and the
role it plays in high performance
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
Alex Chen, PhD
ALUMINUM EXTRUSION DESIGN
AND THE ROLE IT PLAYS IN HIGH
ANGEL ROSARIO, ALEX CHEN, MIKE TOZIER
Introduction of Sapa Group
Aluminum Extrusion Design
Thermal Design Considerations
High Performance Cooling Solutions
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
SAPA EXTRUSIONS AMERICAS
Sapa Extrusions North America offers design, manufacturing, fabrication and finishing of
aluminum extrusions through 25 facilities located across North America.
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
Profile type and circle size
Thin walls or sharp corners
Thick to Thin Ratio (variable bearings)
PRODUCT DESIGN COST FACTORS
Type of Profile
Alloy / Temper
6063 vs. 6061
Thin? Thin to Thick?
Standard AA vs. Tighter
Long Lengths vs. Short Lengths
Low production cost
Low die cost
Tooling could break sooner
Higher material and die cost
Higher Material and Tooling Cost
Multi-Void hollows have the highest cost
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
Circle size is one of the factors for
determining the appropriate size press a
Sapa is able to extrude profiles with
circle sizes up to 22” in North America.
MINIMUM WALL THICKNESS
Recommended minimum wall
thickness for 6063 Alloy are shown in
the guidelines. (Add 15% for 6061
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.
Uniform wall thickness
Tongue ratio reduction
Incorporating useful features
ID Mark, drill points, screw slots, location/registration stops
Convert hollows to solid profile
HEAT SINK RATIO
Fin height to gap ratio is typically limited to 16:1.
ALUMINUM USED IN COOLING SOLUTIONS
Aluminum heat sinks and liquid coolers have been widely used as
cooling components in power electronics, LED lighting, computers,
telecom devices, healthcare, automotive, etc.
Recyclable & Non-toxic
Complex integral shapes
Short lead times
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
Friction Stir Welding is a solid-state joining method, which has been used
in the welding of aluminum since 1991.
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
No filler metal (parent metal conductivity)
High tensile, fatigue, and bend properties
Void free and leak proof
Low thermal distortion and shrinkage
Suitable for automation