Thermal Design Solutions

Work Flow

Production Plants

Outside Contractors

Sapa Sales Force

Application Center

Customer Engineers

Customer Buyers

Sapa Technical Service

Thermal Design Center

Sapa Technology

Agreement Sapa-Customer: ●NDA

●Commercial

Added Value

Design:

Thermal simulations

Geometry optimization

Weigh reduction

Components integration

Extrusion

High fin ratio

Productivity enhancements

Surface quality

Fabrication

CNC machining

FSW, MIG welding, brazing

Anodizing, electro coloring

Supply Chain

Delivery time – transportation

Packaging

Consumer stock

Turn key solutions

Why extruded profiles

Heat and electrical conductivity; Corrosion resistance; Mechanical strength; Low weight; High efficiency due to high Fin Ratio* Surface quality; Easy to process and machine; Low investments in dies; Recycling (environmental friendly)

*Fin Ratio = Fin height gap width

Power dissipation

0

50

100

150

200

250

pure aluminium extrude Al-alloys cast Al-alloys

ther

mal

con

duct

ivity

, W/m

K

Thermal conductivities• Pure aluminium: about 230 W/mK (difficult to machine)

• Extruded alloy 6060 HC (T6,T61): about 200 - 215 W/mK

• Cast alloys: about 120 -140 W/mK

• Copper (pure): 390 W/mK (much heavier and more expensive)

Thermal conductivities*

Extrusion alloy 6063

Die-Cast alloy AlSi10

* At room temperature

Our Capabilities For Thermal Design

3D Modelling with parametric CAD (Solid Works ® Professional v.2010) Interferences analysis; Cinematic analysis; Fabrication study; 3D Render;

3D Modelling

Symulations with Sapa Software

Sapa Convection and Radiation The software makes suppositions about different orientations and bases the calculation on these suppositions. The input data are heat dissipation and requirements and operating ambient temperature.

Sapa Cool Quick and easy tool for simulating the performance of a cooling device. The program begins with the warmest point on a cooling device and designs the rest of the component on the basis of that point.

CFD and FEM Analysys

ANSYS Fluent: Computational fluid dynamic, particularly effective for carrying out detailed studies of new products at an early stage of the design process, such as simulating the flow of air, liquids and heat around cooling devices.

ANSYS Mechanical: Finite element method analysis for steady state thermal problems. Is it possible to perform very fast simulation in order to reduce both the development time and costs.

Experimental measurements

The Wind Tunnel* makes it possible to verify calculations carried out using Rapid Cool and/or CFD analysis, and hence check the actual performance of the cooling device. The tunnel can accommodate cooling devices measuring up to 500 x 500 mm.

FLIR*: Measurement with thermo element and IR photometer. The IR photometer helps in determining the emissivity of different surface treatments so that can be suggested a suitable, cost-effective surface treatment.

Prototypes and Tests

We can support our customers in testing and prototyping: ● Mechanical: pull test, hardness, fracture toughness, pressure test; ● Dimensional evaluations and non distructive controls; ● Long term analysys: fatigue and corrosion; ● Prototyping: 3D printing – CNC machining – electro erosion ● Specific test requested by the customer.

Heat Sinks Extrusion Capabilities*

h w Sapa Profiles Fossanova

Max. Size (w x h) 420 x 40 mm Min. Section Weight 700 g/m Max. Section Weight 25.000 g/m Min. Fin Thickness 1,2 mm Max. Fin Ratio (R) Guaranteed up to 8

*IMPORTANT All values are for reference only. For each RFQ, please ask for a feasibility study.

h1

w1

R = h1

w1 Sapa Profiles Feltre

Max. Size (w x h) 400 x 40 mm Min. Section Weight 700g/m Max. Section Weight 28.000 g/m Min. Fin Thickness 1.2 mm Max. Fin Ratio (R) 14

Success Stories inThermal

Applications

Heat sink for inverters

LED Lighting

Liquid cooling / heating

Modular heat sink

Different systems can be proposed, for assembly concept, fin shape and number of extruded parts. All the solutions will have to be improved and developed according to the customer feedback.