Die Casting of Lightweight Thin Fin Heat Sink Using Al-25%Si

1. Overview:

  • Title: Die Casting of Lightweight Thin Fin Heat Sink Using Al-25%Si
  • Authors: Toshio Haga and Hiroshi Fuse
  • Year of Publication: 2024
  • Journal/Conference: Metals (MDPI)

2. Research Background:

The demand for lightweight and cost-effective heat sinks is increasing. Die casting is a common and economical method for producing complex-shaped heat sinks. To reduce weight, a typical approach involves thinning the fins and base of the heat sink. Previous research explored alternative casting methods like semisolid casting, high-density casting, and high-vacuum die casting to achieve thinner fins. However, these methods often require specialized and expensive equipment, increasing production costs. Composite materials offer lightweight solutions with good thermal conductivity, but their complex processing, high material cost, and recyclability challenges limit their widespread adoption. This study aims to leverage the superior fluidity of Al-25%Si aluminum alloy to overcome the limitations of traditional die casting when producing thin fins and bases, utilizing a conventional die casting machine for cost-effectiveness.

3. Research Objectives and Questions:

  • Research Objective: To investigate the feasibility and characteristics of producing lightweight thin-fin heat sinks using Al-25%Si aluminum alloy with a conventional die casting machine. The study aims to assess the heat dissipation performance and weight reduction achieved compared to traditional aluminum alloys and commercial heat sinks.
  • Key Research Questions:
    • How does the fluidity of Al-25%Si compare to that of conventional aluminum die casting alloys (e.g., ADC12)?
    • What are the effects of fin thickness, fin height, number of fins, and base thickness on heat dissipation and weight reduction in Al-25%Si heat sinks?
    • How does the heat dissipation performance and weight of the Al-25%Si heat sink compare to a commercial heat sink?
  • Research Hypothesis: The superior fluidity of Al-25%Si allows for the creation of thinner fins and bases in a conventional die casting process, leading to a lighter weight heat sink without compromising heat dissipation performance.

4. Research Methodology:

  • Research Design: Experimental design. The study used a 500 kN cold chamber die casting machine to produce a series of Al-25%Si heat sinks with varying parameters (fin thickness, fin height, number of fins, base thickness). A control group using ADC12 was also included for comparison.
  • Data Collection Methods: Heat dissipation was measured using a micro-ceramic heater with a thermal interface material. Flow length was assessed using spiral dies. Microstructure analysis was performed using optical microscopy. Weight measurements were conducted.
  • Analytical Methods: ANOVA and other statistical methods were used to analyze the data. Optical microscopy was employed for microstructural characterization.
  • Research Subjects and Scope: The study focused on Al-25%Si and ADC12 aluminum alloys, comparing the properties of heat sinks with varying design parameters. A commercial heat sink was used as a benchmark for comparison.

5. Main Research Results:

  • Key Findings: Al-25%Si exhibited significantly higher fluidity than ADC12. Thin fins (0.5 mm thickness, 0.5° draft angle) were successfully cast using Al-25%Si and a conventional die casting machine. Fin thickness did not significantly affect heat dissipation, but it did affect weight. Increasing fin height, number of fins, and base thickness improved heat dissipation, but the effect of fin height was most significant, particularly under constant weight conditions. Porosity and microstructural non-uniformity had minimal effects on heat dissipation. The Al-25%Si heat sinks demonstrated comparable heat dissipation performance but significantly lower weight (up to 68% reduction) compared to the commercial heat sink.
  • Statistical/Qualitative Analysis Results: Detailed statistical analysis supporting these findings is present in the full paper. Qualitative observations from optical microscopy provided insight into the microstructural characteristics of the cast Al-25%Si.
  • Data Interpretation: The superior fluidity of Al-25%Si enabled the creation of lightweight, high-performance heat sinks with thin fins. The results suggest that optimizing fin height is crucial for efficient heat dissipation in lightweight designs.
  • Figure List and Description: The figures in the full paper would visually represent the data on fluidity comparison, heat dissipation performance under varying parameters, microstructural analysis, and comparison with the commercial heat sink.
Figure 2. Schematic diagram of heat sinks.
Figure 2. Schematic diagram of heat sinks.
Figure 5. Die casting of heat sinks using ADC12 and Al-25%Si.
Figure 5. Die casting of heat sinks using ADC12 and Al-25%Si.
Figure 29. Photograph and size comparison with the commercial heat sink: (a) commercial heat sink and (b) type F heat sink of this study.
Figure 29. Photograph and size comparison with the commercial heat sink: (a) commercial heat sink and (b) type F heat sink of this study.
Figure 31. Photograph of high-ceiling LED lamp heat sink cast using Al-25%Si.
Figure 31. Photograph of high-ceiling LED lamp heat sink cast using Al-25%Si.

6. Conclusion and Discussion:

The study successfully demonstrated the feasibility of producing lightweight, high-performance heat sinks using Al-25%Si and a conventional die casting process. The superior fluidity of Al-25%Si allowed for the creation of significantly thinner fins than typically achievable with traditional die casting alloys. Optimization of fin height was identified as a key factor for maximizing heat dissipation under weight constraints. The Al-25%Si heat sinks demonstrated comparable heat dissipation performance to a commercial heat sink while achieving significant weight reduction. The findings highlight the potential for Al-25%Si in cost-effective manufacturing of lightweight heat sinks for various applications, particularly in automotive and high-ceiling LED lighting. Further research could focus on the impact of porosity, microstructural uniformity, and exploring other Al-Si alloys.

7. Suggestions for Future Research:

  • Further investigation into the influence of porosity and microstructural variations on heat dissipation performance.
  • Comparative studies of different Al-Si alloys to optimize alloy composition for thin-fin heat sink manufacturing.
  • Experimental validation of heat sink performance under real-world operating conditions.
  • Cost-benefit analysis comparing Al-25%Si with other materials for heat sink applications.

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Tags: ADC12; ,Al-Si alloy; ,aluminum alloy; ,aluminum alloys; ,Aluminum Die casting; ,ANOVA; ,Applications; ,Die casting; ,Draft; ,Heat Sink; ,Microstructure; ,자동차; ,해석