Aluminum Heatsink Extrusions – Stocked & Custom

Aluminum extrusion involves forcing billets through a die. This is the best option for complex cross section aluminum heat sinks. Besides, die engineering incur significantly lower costs in comparison to castings. Extruded aluminum heat sinks also have fine finishes and generate stronger products. The only shortcoming of this option is the size constraints.

On the other hand, die cast heat sinks are made when molten aluminum is forced into a mold. After that, time is given to the billet to allow the molten aluminum to solidify. Unfortunately, the casting process is slower and produces end products with seams and imperfections.

Active aluminum heat sinks are used in combinations with fans, water pumps, or air blows among other technologies to achieve more effective heat dissipation results. The active heat sinks are the most commonly used sinks in combinations as they’re utilized for temperature control.

This ensures that they not only control temperature and protect the equipment but also enhance their performance. Aluminum heat sinks are also combined with heat pipes for better cooling of the equipment.

We use two major aluminum alloys including alloy 6061 and 6063. We use the T5 and T6 tempers for the 6061 alloys to produce aluminum heat sink extrusions.

We also use T5 tempers for alloys 6063. It offer the best thermal and mechanical properties for aluminum heat sink extrusion production.

Most equipment that uses electrical current to function generates heat in the process. Once this heat is generated, it must be removed from source for the equipment to continue working optimally. Aluminum heat sinks are strategically positioned to catch the heat produced from the source through conduction.

Depending on whether the aluminum heat sink is active or passive, the heat will be moved from high to low temperature areas. Temperature gradient allows this to happen seamlessly.

During operations, aluminum heat sinks tend to be hotter towards the area producing heat and cooler towards the outer area of the sink.

During production, thermal gradient is established based on operational needs. When the heat sink is functioning, this gradient determines how effective the heat sink will be.

Heat sinks that work with fluids ensures that the fluid passes through the area with excessive heat and spreads the heat to the cooler areas. This is then transferred to areas with the least heat and consequently dissipate to the air.

Our aluminum heat sink starts with aluminum extrusion, then cutting and CNC machining, and completes with mill finish or anodizing. Aluminum billets are forced through a die and the products cut into the right sizes.

Aluminum extrusion is a cost-effective way of manufacturing aluminum heat sinks and also allows our team to create complex heat sink extrusions at very reduced costs.

Once the extrusion has been formed, it’s cut to the desired length based on requirements. Although, extrusion has a limitation regarding heat sinks development. It limits the product’s width to some extent.

Aluminum heat sinks are applied in various industries that require continuous cooling for their equipment to work optimally, consistently, and reliably. Below are some of the most common heat sink applications:

• Telecommunications industry

Aluminum heat sinks are an integral part of equipment used in the telecommunications industry. For instance, routers are important network transmitters. During these transmissions, there’s a lot of heat production. Heat sinks plays an important role in the dissipation of the energy to allow the devices cool down and keep working optimally.

• Computers and electronics

Super computers require lots of energy to function. They also emit massive heat in the process. Aluminum heat sinks help to cool down the CPUs and GPUs thereby keeping the computers in the right working conditions.

• LED lighting

Continuously lighting leads to emission of heat. Heat sinks help to cool the system and elongate its lifespan.

• Automotives

Electric and hybrid vehicles produce a lot of heat during movement. They must be cooled to allow proper functioning lest the vehicles overheat and stops working properly. Aluminum heat sinks help dissipate the heat therefore cooling the vehicles, especially the engine area.

There are multiple aluminum heat sinks available in the market. Let’s look into the below heat sinks you definitely want to know about.

• Stamping Heat Sink

Aluminum sheets are stamped in press in a process called die stamping to make stamping heat sinks. The designs are based on the intended application.

The result is two parts of heat sinks with base and stamped fins. The fins increase the heat sink’s strength and gives the manufacturer an opportunity to make multiple sink designs.

• Folded Fin Heat Sinks

Folded fin heat sinks are produced by bending aluminum material in a fan/fin shaped structure. The result is thinner heat sinks with relatively higher aspect ratios.

The fins are then soldered to base for strength. In addition, heat pipes may be introduced for heat transfer. Since there are passive heat sinks, they’re used in combination with a fan to ensure proper air flow.

• Machining Heat Sinks

This is accomplished through laser and CNC machining. The aluminum heat sinks produced are very economical but designs are limited.

• Extruded Heat Sinks

These ones are cost effective and offer one of the best thermal performances. They are produced through extrusion using alloy 6063-T5. The alloy is utilized because of superior mechanical properties as well as thermal attributes. We can attest that it’s true the extruded aluminum heat sinks bear low production costs, especially when produced in large quantities.

• Standard Extruded Heat Sinks

We, at FONNOV Aluminum offer variety of heat sinks upon request. Our standard extruded heat sinks have been expertly developed through extrusion with proper and standard procedures observed. After extrusion, the heat sinks are cut according to requirements, machined, and finally anodized.

We also elongate the sinks after production. This customization allows us to meet client specific needs especially those that are size related.

We have round and straight standard heat sinks. The round standard extruded heat sinks are of two types including hollow and solid type. Their outside diameter (OD) and inside diameter (ID) vary in ratios.

The straight fin type heat sink has ratios calibrated in mm, measured as weight versus height. The ratios available on our stock range vary a lot.

• Thermal Requirements

When considering this factor, you must ask yourself how much heat can the heat sink you want dissipate? Answering this correctly means you’ve already established the amount of energy your device needs the heat sink to take care of. Once you’ve determined this, you’d be having the correct information to choose the right extruded aluminum heat sink.

• Active or Passive Heat Sinks?

Active heat sinks utilize fluid to dissipate heat. On the other hand, passive heat sinks manipulate air flow to accomplish the same, only minus fluids. Therefore, each of these heat sinks have different applications.

This means you must understand the environment under which you want your heat sink to operate. That way, you can match the heat sink specifications with the environmental requirements needed for your device.

• Thermal Resistance Formula

A heat sink must efficiently conduct heat and effectively dissipate it. To accomplish this, we follow the thermal resistance formula to the latter. The formula ensures we produce the right extruded aluminum heat sink for your products.

• Thermal Interface Material

The material joining the heat sink and the device in need of heat dissipation plays an important role in achieving efficiency. The gap filler also known as thermal grease must be of the correct gradient for efficient heat transfer. Conversely, the device must be compatible to the gap filler. On our end, we design and produce extruded aluminum heat sinks that are easily compatible with gap fillers.

Aluminum alloys are considered the best options for making heat sinks for the following reasons.

• Easy to Fabricate

Aluminum is light and soft. This makes it easy to bend, weld, or cut the metal into different shapes. Heat sinks can be large or small in size but have complicated shapes and designs that require easy-to-fabricate materials.

• Light Weight

Aluminum is three times lighter than steel. Its volume while in solid state determines its weight after extrusion. Overall, it has a reduced atomic weight which makes it lighter than most of the other available options like steel.

The aluminum alloy 6063 and 6061 for heat sink extrusion has a density of 2.7 Kg/m³ when in solid form which reduces to 2.36 Kg/m³ after conversion to liquid. This contributes to its final size which is smaller and lighter than the others.

After extrusion, the small size and lightweight comes in handy especially during application. Electronic device manufacturers don’t have to struggle about making heavier and larger machines to accommodate heat sinks.

• Cost-Effective

Costs are an important factor to consider in mass production. Aluminum fits the bill with its affordability and ready availability. Besides, it lowers non-recurring engineering costs, therefore making their overall production costs lesser.

• Thermal Conductivity

Aluminum alloys 6063 and 6061 have desirable thermal conductivity scores between 166 and 201 W/(m.k). Within them, there are valence shells that hold three electrons which make random movements and are loosely inclined towards the nucleus.

The electrons carry charge that facilitate electricity conduction. They move in harmony once current is detected. This action ensures that higher thermal conductivity is achieved.

• Can be anodized

Sustainability must be looked into when manufacturing heat sinks. Aluminum can be anodized to make the heat sink more corrosion resistant and with better adhesion.

This is a heat sink manufactured through aluminum extrusion process to be used for heat dissipation in an array of electronic devices. The heat sink formation process is complete after aluminum is pushed through a special opening by force in a single strike. The punch must be sudden for proper heat sink formation.

To achieve desired results, we use a cross sectional die structure to give the heat sinks specific shapes. The manufacturing requirements for heat sink extrusion make them suitable for mass production. This has helped us cut on non-recurring engineering costs and therefore allocate more funds on quality assurance.

We reckon that proper heat management is important for electronic devices especially in critical industries like the medical industry. We use high quality dies and aluminum ingots for production. Instead of aluminum scrap, we manufacture heat sinks using top standard aluminum billet. This helps produce proper heat sinks that will accomplish effective heat dissipation.