High Density Die Casting (HDDC): new frontiers in the manufacturing of heat sinks

Andrea Sce1 and Lorenzo Caporale1

Published under licence by IOP Publishing Ltd
Journal of Physics: Conference SeriesVolume 525Eurotherm Seminar 102: Thermal Management of Electronic Systems 18–20 June 2014, Limerick, Ireland

Citation Andrea Sce and Lorenzo Caporale 2014 J. Phys.: Conf. Ser. 525 012020DOI 10.1088/1742-6596/525/1/012020


Finding a good solution for thermal management problems is every day more complex. due to the power density and the required performances. When a solution suitable for high volumes is needed. die-casting and extrusion are the most convenient technologies. However designers have to face the well-known limitations for those processes. High Density Die Casting (HDDC) is a process under advanced development. in order to overcome the extrusion and traditional die casting limits by working with alloys having much better thermal performances than the traditional die-casting process. while keeping the advantages of a flexible 3D design and a low cost for high volumes. HDDC offers the opportunity to design combining different materials (aluminium and copper. aluminium and stainless steel) obtaining a structure with zero porosity and overcoming some of die-casting limits. as shown in this paper. A dedicated process involving embedded heat pipes is currently under development in order to offer the possibility to dramatically improve the heat spreading.

Figure 4. CFD comparison between traditional DC (left) and HDDC (right); HDDC allow more fins
Figure 4. CFD comparison between traditional DC (left) and HDDC (right); HDDC allow more fins


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