Fri. Jun 21st, 2024

Guide to Extrusion Profile Heat Sinks

Extruded metal heat sinks are some of the lowest price, widest used heat spreaders in electronics thermal management. Besides their affordability, extruded heat sinks are lightweight, effectively cut to size and form, and able to high stages of cooling.

Steel selections

Most extruded heat sinks are crafted from aluminum alloys, mainly from the 6000 alloy collection, in which aluminum dominates. Trace amounts of other elements are brought, including magnesium and silicon. These alloys are clean to extrude and gadget, are weldable and may be hardened.

Not unusual alloys for extruded heat sinks are the 6063 metals. Those may be extruded as complex shapes with very smooth surfaces. In addition, 6061 aluminum is also used for extrusions. Its tensile electricity (as much as 240 mpa) is advanced to 6063 alloys (up to 186 mpa). Similarly to heat sinks, those aluminum alloys are popular for architectural packages, including window and door frames.

The surfaces of these metals can be anodized to update their occurring surface layer of aluminum oxide. Anodizing provides an extra heat switch, corrosion resistance, and better adhesion for paint primers. It’s far an electrochemical procedure that increases floor emissivity, corrosion, resistance, and electrical isolation.

The Extruding process

Aluminum alloys are popular for extruding heat sinks because they offer each malleability and formability. They can be effortlessly machined and are as low as one-1/3 the density of steel. This extrusion outcome can be sold at a discounted price relative to different materials.

The aluminum extrusion method starts with designing and developing the die to shape the heat sink profile. Once finished, a cylindrical billet of aluminum is heated up in a forge to high temperatures, typically between 800-925°F (427-496°C). Next, a lubricant is brought to the aluminum to prevent it from sticking to any equipment. It’s far then positioned on a loader, and stress is carried out with a ram to push heated aluminum thru the die.

All through this system, nitrogen is delivered to prevent oxidation. The extruded part will bypass the die and the alternative aspect. It has now been elongated inside the form of the die establishing. The completed Aluminum extrusion is then cooled, and if vital, a method of straightening and hardening creates the finished product.

They can be reduced to the preferred lengths, drilled and machined, and undergo a final aging procedure before being prepared for the marketplace.

Completed heat sinks typically come with anodized surfaces, which could beautify their overall thermal performance. Alternatively, a chromate end provides a little corrosion safety or can be used as a primer earlier than the very last paint, or powder coating is applied.

Shapes of Extruded Heat Sinks

Extruded heat sink profiles vary from easy flat lower back fin systems to complex geometries for optimized cooling. They use it for herbal (passive) or compelled convection (energetic) with an added fan or blower. Extruded profiles can also include unique geometries and groove patterns with a clip or push pin attachment systems.

Extrusions also are available in bulk lengths, e.g., 8 ft, which may be cut to one-of-a-kind lengths in line with client desires.

Optimizing Thermal overall performance

6063 aluminum alloy has a thermal conductivity of 201-218 W/(mk). Higher tensile electricity 6061 aluminum’s thermal conductivity ranges from 151-202 W/(mk).

Besides choosing the aluminum heatsink alloy, selecting a most excellent extruded heat sink must element in its average dimensions and weight, the desired thermal resistance, and the extrusion form (flat-lower back, flat-back with an opening, hollow, double-sided, and so on.).

Extruded heat sinks can be designed with skinny, and thus extra, fins than other sink kinds. They may be extruded with factor ratios of around eight:1, which could substantially optimize heat sink overall performance. A heat sink’s element ratio is essentially the evaluation of its fin top to the space among its fins.

In standard heat sinks, the aspect ratio is between 3:1 and 5:1. A excessive element ratio heat sink has taller fins with a smaller distance between them for a balance that may be eight:1 to sixteen:1 or extra.

For that reason, an excessive component ratio heat sink provides a more density of fins in a given footprint than with a more excellent, unusual length sink. The exceptional advantage is its improved quantity of heat dissipating surface location due to its additional fins. Similarly, those heat sinks no longer occupy any greater length or width. The result is a more efficient heat sink with higher performance consistent with a gram in the identical footprint.


An extruded heat sink boosts the surface location available for heat transfer from excessive-power semiconductor devices, reducing a given semiconductor’s external case temperature and inner junction temperature.

It lets the semiconductor devices carry out at their highest degree, with maximum reliability. Such semiconductor devices encompass (but are not limited to) RF strength transistors, RF energy amplifiers, energy mosfets, igbts, inverter electricity modules, and thyristor modules.