What Are Extruded Heat Sink Materials?

Extruded Heat Sinks are highly effective thermal management solutions. Their function is to dissipate heat from high-technology/non-high-technology devices so the heat is not generated by the device itself. More so, these component parts are critical to enhancing the performance of high-technology devices and providing a longer life span for these devices. Therefore, understanding what extruded heat sinks are made of and how they are manufactured will help potential purchasers understand what extruded heat sinks are available to purchase.

Common Materials Used in Extruded Heat Sinks

Aluminum (i.e., aluminum alloys - 6061 and 6063) is the most common material used for manufacturing extruded heat sinks. These materials have highly desirable properties, which include being lightweight, being versatile with high thermal conductivity, having good corrosion resistance, and being low cost. Furthermore, aluminum can easily be extruded into various sizes and shapes, making it a good material choice for most applications.

Copper, or some combination of copper and aluminum, is used in some specialized applications where copper has a much higher thermal conductivity than aluminum but is much heavier, more expensive, and more difficult to extrude. As a result, it is used in applications requiring a high degree of thermal conductivity in a limited amount of volume.

An anodized extruded heat sink is commonly used to create a more durable and corrosion-resistant heat sink. Anodizing is carried out by oxidizing or treating the surface of aluminum to create a protective oxide layer to protect its surface from wear and oxidation. One type of black anodized extruded heat sinkis both aesthetically appealing and revolutionary in improving heat dissipation through high emissivity.

Extrusion Heat Sink Procedure

The extrusion technique is essential to achieving dependable, high-performance heat sinks. The method involves using an extruded aluminum billet that is heated and forced through a die to create a distinctive, uniform cross section (shape). Below is an overview of this method:

1. Billet Heating - The aluminum is heated to a specific temperature allowing for adequate malleability for performing the extrusion function.
2. Extruding - The hydraulic pressure presses the warm aluminum through the die, providing an end product with the desired profile (cross-section).
3. Cooling/Cutting - The extruded material is cooled and cut to length.
4. Post Processing - The aluminum can be post-processed as required by the design and thermal performance requirements by performing a surface modification such as anodizing, CNC machining, or drilling (mounting holes).

For example, a CNC machined extruded heat sink is an example of a heat sink that is processed after the extrusion process for added dimensional accuracy or specific features such as mounting holes to simplify the installation.

Extruded Heat Sink Types

Within the heat sink category of extrusion, there are a number of different types of heat sinks available that meet specific purposes:

High Thermal Conductivity Extruded Heat Sink: A High Thermal Conductivity Extruded Heat Sink offers maximized heat dissipation efficiency. This is why it is a good choice for devices with a high average power output (examples: LED lights, power inverters).

Dense-Fin Extruded Heat Sink: The Dense-Fin Extruded Heat Sink creates a much larger amount of surface area by using closely spaced fins. This provides great thermal performance by maximizing the contact area to dissipate heat. This design is excellent for designs that must remain compact and do not have any heat dissipation limitations.

Anodized Extruded Heat Sink: The Anodized Extruded Heat Sink has an anodized, or environmentally controlled, finish that improves the heat transfer properties of the heat sink while providing a corrosion-resistant physical barrier around the surface of the heat sink.

Black Anodized Extruded Heat Sink: Black anodizing, like regular anodizing, provides an aesthetically attractive appearance and generally improves the thermal emission characteristics of a heat sink. Because of this, manufacturers are frequently using these heat sinks in applications such as consumer electronics and automotive.

The Reason to Use Aluminum Extruded Heat Sinks

Aluminum extruded heat sinks represent a very favorable balance between thermal conductivity and cost. That's why they are in such high demand for applications ranging from consumer electronics to power/signal distribution.

1. Most Aluminum Has High Thermal Conductivity: Although aluminum has a relatively low thermal conductivity when compared to copper, it is still high enough for most applications.

2. Lightweight: Aluminum is considerably lighter than copper; therefore, it will be used in applications where weight is a determining factor (examples include aerospace and handheld devices).

3. Cost: Aluminum is a much cheaper metal than copper and therefore is used in higher quantities to produce aluminum extruded heat sinks than copper heat sinks due to the amount of copper scrap created during manufacture, since copper prices fluctuate considerably. Extruded aluminum heat sinks can be used to create intricate heat sink designs that meet the thermal requirements of many products.

Extruded Heat Sink Applications

Extruded aluminum heat sink solutions can provide thermal management; therefore, they are used in many industries, including:

- Consumer Electronics: Examples of consumer electronics where aluminum heat sinks are used include smartphones, laptops, and gaming consoles, which all rely on heat sinks to effectively dissipate heat.

- Automotive: All electric vehicles and engine control units rely on heat sinks to keep these components cool and operating properly.

- Industrial Equipment: Both high-powered machinery and LED lighting systems effectively manage heat using extruded heat sinks.

- Telecommunications: Cooling network devices and servers to provide operation and uptime requires the use of extruded heat sinks.

- Renewable Energy: Solar and wind inverter applications rely on extruded heat sinks with high thermal conductivity to assist with heat management.

Frequently Asked Questions: Considerations for Buyers

Consider the following information when purchasing extruded heat sinks:

Material: Choose an extruded heat sink made of high-quality aluminum or copper depending on the thermal requirements you need for your application.

Surface Finish: Choose an anodized extruded heat sink for better durability and efficient heat dissipation.

Design: Assess the fin density, dimensions, and mounting to ensure that the extruded heat sinks you select are compatible with your application design. When using extruded heat sinks in compact designs, selecting a heat sink with a higher fin density is recommended.

Customization: Look for a manufacturer that can provide CNC machined extruded heat sinks for more accuracy and any special design requirements you may have.

Extruded heat sinks are one of the most critical components used for thermal management in electronic devices. A buyer can continue to make informed, customized decisions on how to apply extruded heat sinks based on their understanding of the material used, the manufacturing processes employed, and the applications of extruded heat sinks so that they achieve the maximum performance and reliability in their application. If you are looking for a black anodized extruded heat sink for aesthetics or high thermal conductivity extruded heat sink for industrial applications, a solution exists to meet your needs.