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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
 Ha...
Moderator Presenters
Paul Heney
Design World
Mike Tozier
Sapa Extrusions
Americas
Alex Chen, PhD
Sapa Extrusions
Americas
...
ALUMINUM EXTRUSION DESIGN
AND THE ROLE IT PLAYS IN HIGH
PERFORMANCE COOLING
SOLUTIONS
ANGEL ROSARIO, ALEX CHEN, MIKE TOZIE...
OUTLINE
5
Introduction of Sapa Group
Aluminum Extrusion Design
Thermal Design Considerations
High Performance Cooling Solu...
SAPA GROUP
6
Sapa is the world leader in aluminum solutions – a new company that joined the aluminum
extrusion businesses ...
SAPA EXTRUSIONS AMERICAS
7
Sapa Extrusions North America offers design, manufacturing, fabrication and finishing of
alumin...
PROFILE DESIGN
8
What is the goal?
Design the optimal profile that fulfills the demands of the application at
the lowest p...
TOOLING COST FACTORS
Die Breakage
Alloy
Profile type and circle size
Non-fill condition
Thin walls or sharp corners
Thick ...
PRODUCT DESIGN COST FACTORS
Type of Profile
Solid
Semi-Hollow
Hollow
Alloy / Temper
6063 vs. 6061
Wall Thickness
Thin? Thi...
PROFILE CLASSIFICATIONS
Solid
Low production cost
Low die cost
Semi-Hollow
Tooling could break sooner
Higher material and ...
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,...
MINIMUM WALL THICKNESS
Recommended minimum wall
thickness for 6063 Alloy are shown in
the guidelines. (Add 15% for 6061
Al...
GEOMETRY CONSIDERATIONS
15
Symmetry
Uniform wall thickness
Large radii
Tongue ratio reduction
Incorporating useful feature...
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 i...
ALUMINUM EXTRUSIONS
20
Recyclable & Non-toxic
Lightweight
Strong
Corrosion resistant
Thermally conductive
Reflective
Elect...
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
...
SIMULATION
30
SIMULATION
31
Critical items needed for design support:
Max junction temp (Tj) or thermal resistivity requirements
Ambient...
FRICTION STIR WELDING
32
Friction Stir Welding is a solid-state joining method, which has been used
in the welding of alum...
METHOD
33
WELD STRUCTURE
34
Fully re-crystallized fine grain micro-structure is created in the nugget by
the intense plastic deforma...
ADVANTAGES OF FRICTION STIR WELDING
35
No filler metal (parent metal conductivity)
High tensile, fatigue, and bend propert...
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 ...
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 An...
CONTACT
49
Alex Chen, PhD
Sr. Application Engineer
Sapa Extrusions Americas
Alex.Chen@sapagroup.com
801-450-7221
Angel Ros...
Questions?
Paul Heney
Design World
pheney@wtwhmedia.com
Phone: 440-234-4531
Twitter: @DW_Editor
Mike Tozier
Sapa Extrusion...
Thank You
 This webinar will be available at
designworldonline.com & email
 Tweet with hashtag #DWwebinar
 Connect with...
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Aluminum Extrusion Design And The Role It Plays In High Performance Cooling Solutions

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

  1. 1. Aluminum extrusion design and the role it plays in high performance cooling solutions
  2. 2.  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
  3. 3. Moderator Presenters Paul Heney Design World Mike Tozier Sapa Extrusions Americas Alex Chen, PhD Sapa Extrusions Americas Angel Rosario Sapa Extrusions Americas
  4. 4. ALUMINUM EXTRUSION DESIGN AND THE ROLE IT PLAYS IN HIGH PERFORMANCE COOLING SOLUTIONS ANGEL ROSARIO, ALEX CHEN, MIKE TOZIER 4
  5. 5. OUTLINE 5 Introduction of Sapa Group Aluminum Extrusion Design Thermal Design Considerations High Performance Cooling Solutions
  6. 6. 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.
  7. 7. SAPA EXTRUSIONS AMERICAS 7 Sapa Extrusions North America offers design, manufacturing, fabrication and finishing of aluminum extrusions through 25 facilities located across North America.
  8. 8. 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.
  9. 9. 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
  10. 10. 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
  11. 11. 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
  12. 12. CIRCLE SIZE DIAMETER 12
  13. 13. 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
  14. 14. 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
  15. 15. GEOMETRY CONSIDERATIONS 15 Symmetry Uniform wall thickness Large radii Tongue ratio reduction Incorporating useful features ID Mark, drill points, screw slots, location/registration stops
  16. 16. GEOMETRY OPTIMIZATION 16 Convert hollows to solid profile
  17. 17. HEAT SINK RATIO 17 Fin height to gap ratio is typically limited to 16:1.
  18. 18. DAMAGED DIE 18
  19. 19. 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.
  20. 20. 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
  21. 21. THERMAL CONDUCTIVITY 21 Copper (pure): 395 W/mK
  22. 22. EXTRUSION ALLOY VS. DIE-CAST ALLOY 22
  23. 23. PROFILE DESIGN 23
  24. 24. PROFILE DESIGN 24
  25. 25. PROFILE DESIGN 25
  26. 26. PROFILE DESIGN 26
  27. 27. PROFILE DESIGN 27
  28. 28. PROFILE DESIGN 28
  29. 29. 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
  30. 30. SIMULATION 30
  31. 31. 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
  32. 32. FRICTION STIR WELDING 32 Friction Stir Welding is a solid-state joining method, which has been used in the welding of aluminum since 1991.
  33. 33. METHOD 33
  34. 34. WELD STRUCTURE 34 Fully re-crystallized fine grain micro-structure is created in the nugget by the intense plastic deformation at elevated temperature.
  35. 35. 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
  36. 36. FSW MODULAR HEAT SINK* 36 *PATENT PENDING
  37. 37. FSW HEAT SINK VS. BONDED FIN HEAT SINK 37 FSW Bonded
  38. 38. METALLOGRAPHIC EXAMINATION 38
  39. 39. THERMAL TESTING SETUP 39
  40. 40. THERMAL RESISTANCE 40 The thermal resistance of FSW modular heat sink is 8% lower than bonded fin design. *THE DEFINITION OF THERMAL RESISTANCE:
  41. 41. EXTRUDED FSW LIQUID COOLER* 41 *PATENTED BY SAPA
  42. 42. METHOD 42 The liquid cooler is sealed by friction stir welding the lids to the extruded body.
  43. 43. METALLOGRAPHIC EXAMINATION 43
  44. 44. PRESSURE TEST 44 The liquid cooler can withstand burst pressure up to 90 bar.
  45. 45. THERMAL TEST SETUP 45 Double-sided mounting with 1500 Watt per side
  46. 46. THERMAL RESISTANCE 46
  47. 47. PRESSURE DROP 47
  48. 48. 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
  49. 49. 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
  50. 50. 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
  51. 51. 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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