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#DWwebinar
#DWwebinar
The Advantages of Using Extrusions to Solve Thermal
Management Challenges for the Automotive Industry
#DWwebinar
This webinar will be available afterwards at www.designworldonline.com & email
Q&A at the end of the presentation
Hashtag for this webinar: #DWwebinar
Before We Start
#DWwebinar
Mary GannonModerator
Design World
Stephen Jackson Business Development
Mgr., TM ProductsSapa Extrusions NA
The Advantages of Using Extrusions to Solve Thermal Management Challenges for the Automotive Industry
ADVANTAGES OF USING EXTRUSIONS IN THE AUTOMOTIVE INDUSTRY TO
SOLVE THERMAL MANAGEMENT CHALLENGES
JASON WEBER & STEVE JACKSONNOVEMBER 3, 2015
ADVANTAGES OF USING EXTRUSIONS IN THE AUTOMOTIVE INDUSTRY TO SOLVE THERMAL MANAGEMENT CHALLENGES
AGENDA
Who is SAPA
Why Aluminum to Lightweight Vehicles and EV’s
Designing Thermal Extrusions
Extrusions versus Castings
Friction Stir Welding (FSW) of Extrusions
Module Heat Sinks
Extruded Cold Plates
Summary
SHAPING A SUSTAINABLE FUTURE THROUGH INNOVATIVE ALUMINUM SOLUTIONS
Precision tubingProfile-based building systemsValue-added profiles
Present in 40countries
100+ production units
5 business areas: Profiles Europe, Profiles Americas, Profiles Asia, Buildings System, Precision Tubing
~$8.5 billion sales Worldwide$2.4 billion sales America’s
SAPA IN FIGURES
World leader in aluminum solutions
23,000employees worldwide, 6,500 in Americas* 2011 pro-forma
GLOBAL APPLICATION DEVELOPMENTSapa Extrusions’ central product development resource. The team supports customers and regional Sapa resources in developing innovative solutions and products.
Key competencies Aluminum Extrusions Product Design & Optimization Simulation & Analysis Project Management Technology & Knowledge
Transfer
Product expertise Renewable Energy Thermal Management LED Thermal Solutions Marine Engineered Products
LOCAL PRESENCE, AROUND THE WORLD
SAPA IN NORTH AMERICA
Yankton, SD
Portland, OR
City of Industry, CA
Spanish Fork, UT
Burlington, NC
Connersville, IN
Mountain Top, PA
Mississauga, ON
Montreal, QC
Elkhart, IN Cressona, PA
Gainesville, GA
Delhi, LA
Phoenix
St. Augustine
Sidney, OH
KalamazooNorth Liberty, IN
Belton
Toronto, ON
Magnolia, AR
Monett, MO
Sapa shall offer the market innovative, value-enhancing solutions based on profiles and strip in the “green” and lightweight material aluminum.
Sapa shall be perceived as the most attractive partner through a combination of innovation, business know-how and cost effectiveness.
OUR MISSION & VISION
HYBRID THERMAL MANAGEMENTE-Vehicle thermalmanagement
LED Lights
Capacitor Housing(Thermal & Structural)
(Thermal)
(Structural)
(Thermal & Structural)
(Thermal & Structural)
(Thermal & Structural)
ALUMINUM EXTRUSIONS Material Advantages Process Advantages
Recyclable & Non-toxic
Lightweight
Strong
Corrosion resistant
Thermally conductive
Reflective
Electrically conductive
Non-magnetic
Non-sparking
Attractive
Finish Options
Virtually Seamless
Complex integral shapes
Easily assembled
Weldable
Machinable
Cost-effective
Short lead times
WHY COOLING ? HEAT IS THE ENEMY OF ELECTRONICSPerformance: Functional operation of device
Reliability: Temperature dependency of failures
Integrity: Structurally sound and mechanically strong
HEAT is the ENEMY of Electronics
Lack of Strength is the ENEMY of Shock & Vibration
Cost is the ENEMY of Everyone
Aluminum Extrusions can be the SOLUTION
ALUMINUM EXTRUSION SOLUTIONSAluminum Extrusions for Air Cooling
Modular Heat Sinks for High-Fin Ratio requirements
Liquid cooler for power electronics (IGBT, control unit, inverters, converters) and electric motors
Battery enclosures for structural & thermal management
Light-weight parts to light-weight the vehicle
THERMAL CONDUCTIVITY OF ALLOYSTherm al conductivities
0
50
100
150
200
250
pure aluminium extrude A l-alloys cast A l-alloys
ther
mal
con
duct
ivity
, W/m
K
Thermal conductivities:
Diamond is the best, 2,300 W/mKToo expensive
Copper (pure): 390 W/mK (much heavier and more expansive)
Pure aluminium: about 230 W/mK (difficult to extrude)
Extruded alloy AA6063: about 200 -215 W/mK
Cast aluminum alloys: about 120-140 W/mK
TYPICAL HEAT SINKS
COMPUTER SIMULATION
Basic study on heat sinks
Heat sink optimisation (geometry)
Customers specified simulation
Development of own rapid calculation program
Design for Manufacturability
Evaluation of cost factors
Developing the most effective heat sink solutions through the use of CFD/FEM computer simulations.
Sapa developed software for designing and optimizing air cooled
heat sinks.
TECHNICAL EXPERTISE IN THERMAL DESIGN
PROFILE DESIGN
PROFILE DESIGN
FAN CURVE AND WORKING POINT:
Fan working point: Air flow: 0.91 m3/sec (for 4 heat sinks)
Total press-drop: 670 PaAir flow per heat sink:0.23 m3/sec or 820 m3/hour
Pressure drop over heat sink: 520 Pa (670-150=520)
CFD EXAMPLE
20 W
33 W
33 W
3x20 W
4x62.5 W
COMPARISON OF TWO DESIGNS
Thermal testing setup:
LABORATORY TESTING OF COMPUTER DESIGNOver-temperature, measurement vs. calculation (SapaCool)
10,0
15,0
20,0
25,0
30,0
35,0
40,0
45,0
0 10 20 30 40
air flow, m3/hour
over
-tem
pera
ture
1.15 measure1.15 calculation
0.7 measure0.7 calculation
PROFILE DESIGNWhat is the goal?
Design the optimal profile that fulfills the demands of the application at the lowest possible cost.
To design the optimal profile, we must understand factors in production that increase costs.
Fin height to gap ratio is typically limited to 16:1
Example of 7.5:1
TOOLING COST FACTORS
Die Breakage
Alloy
Profile type and circle size
Non-fill conditionThin walls or sharp corners
Thick to Thin Ratio (variable bearings)
Tolerance requirements
PRODUCT DESIGN COST FACTORS Type of Profile
SolidSemi-HollowHollow
Fin Ratio> 6:1; >12:1
Wall Thickness Thin? Thin to Thick?
TolerancesStandard AA vs. Tighter
Cut LengthLong Lengths vs. Short Lengths
FlatnessFly-cut
FabricatingHow many directions
Surface FinishAnodize? Paint?
PROFILE CLASSIFICATIONS
SolidLow production costLow die cost
Semi-HollowTooling could break soonerHigher material and die cost
HollowHigher Material and Tooling CostMulti-Void hollows have the highest cost
CIRCLE SIZE DIAMETER
GEOMETRY OPTIMIZATION
DIFFICULT, MULTI-HOLLOW SHAPES
PROFILE DRAWING
DAMAGED DIE
EXTRUSIONS VERSUS CASTINGS
The vast majority of heat sinks are extrusions or castings
Depending on the criteria and requirements, either can work
Volume and budget are large factors in making the decision
Thermal
ConductivityLack of Porosity Near Net Shape Tooling Costs Piece Part Price
Secondary Machining Required Design
Extrusion 1 1 2 1 2 2 2-DimensionalDie Casting 3 2 1 5 1 1 3-Dimensional
Permanent Mold Casting 4 4 3 3 3 3 3-DimensionalSand Casting 5 5 4 2 5 4 3-Dimensional
1 = Best, 5 = Worst
Not all castings are the same
Do you need a three dimensional solution
Will the design change?
Can the design accept draft angles required for castings?
Is surface finish important?
EXTRUSION ALLOY VS. DIE-CAST ALLOY
TEMPERATURE: 23% REDUCTION OF MAX TEMPERATURE
Existing design (Die Cast)
Sapa’s proposed design (Extrusion)
Notice the difference in temperature only through changing the shape of the fins
THERMAL ANALYSIS OF EXTRUSION VS. CASTING
PROFILE DESIGN
WHAT IF THE RATIO IS TOO BIG TO EXTRUDE?
WHAT IF THE FINAL WIDTH IS TOO WIDE TO EXTRUDE?
HISTORYInvented and patented by the Cambridge, England based The Welding Institute (TWI) in 1991.Sapa, the largest aluminum extruder in Europe, played an active part in the process of converting theory and laboratory experiments into full scale production. In 1996, Sapa started series production in the railway and marine industries.
FRICTION STIR WELDING
DEFINITIONFSW is a method of joining two pieces of metal with no filler material by subjecting the components to heavy plastic deformation, at high temperatures, but lower than the melting point.
FRICTION STIR WELDING
PROCESSA rotating tool is plunged into the components and friction heat is generated. The tool produces severe plastic deformation under high pressure, at which time the weld interfaces are stirred together and a homogenous structure is formed.
FRICTION STIR WELDING
METHOD
FRICTION STIR WELDING
WELD STRUCTUREFully re-crystallized fine grain micro-structure is created in the nugget by the intense plastic deformation at elevated temperature.
FRICTION STIR WELDING
TIG WeldingMIG Welding
FRICTION STIR WELDING
Compared to Fusion Welding, Friction Stir Welding provides:Increased strength (High tensile, fatigue & bend properties)Improved sealing, completely void-free leak proof jointsReduced thermal distortion and shrinkageImproved repeatabilityThe ability to join two different alloysSuitable for automationNo filler metal (parent metal thermal conductivity)Cost effective
FRICTION STIR WELDING
MECHANICAL PROPERTIES
*MATS ERICCSSON AND ROLF SANDSTROM AT THE ROYAL INSTITUTE OF TECHNOLOGY
6082 T6 Aluminum Yield Strength (MPa) Tensile Strength (Mpa) Elongation (%)
Min specification for profile, 5mm 250 295 6
Actual Specimen 291 317 11.3
Pulsed MIG 147 221 5.2
TIG 145 219 5.4
FSW 150 245 5.7
FRICTION STIR WELDING
WIDE EXTRUSIONS:7” Circle Size is the most common width of extrusions21” circle sizes are available, but expensiveWith proper design, there is no limit to the width of a FSW extrusionFSW can penetrate the surface as deep as 20 mmThe base provides an efficient thermal path to remove the heat.
FRICTION STIR WELDING
FRICTION STIR WELDING
This process is usually performed on FSW equipment up to thirty feet long
FRICTION STIR WELDING - CONSISTENTLY ENABLING STRONGER, MORE EFFICIENT STRUCTURES
Renewable Energy (aka Battery) Housings:Super Capacitors are being used to store energy for hybrid and electric vehicles. The capacitors are usually held together via a housing. Thermal management has been a challenge for these, however FSW extrusions are a proven solution. They provide:
Thermal Efficiency
Custom Shapes
Tight fit to capacitor
Structural integrity
Low start-up costs
FRICTION STIR WELDING
FRICTION STIR WELDING
FRICTION STIR WELDING
Another use of FSW has been in the lighting industry where specialized lights are required to be sealed from the atmosphere. Sapa has successfully friction stir welded an aluminum extruded hollow heat sink to a casting end cap to provide a complete seal.
FRICTION STIR WELDING
MOTOR HOUSINGS
BONDED FINS:Definition: Joining an aluminum extrusion or plate to a sheet of aluminum via a thermal epoxy.
Challenges: Manual operation, thermal interference
FRICTION STIR WELDING
SOLUTION: Sapa FSW Module Heat SinksRatios up to 40:18% more thermally efficient than comparable bonded fin heat sinksAutomated processCustom solutions possible
FRICTION STIR WELDING
FSW Bonded
FSW Heat sink vs. bonded fin heat sink:
FRICTION STIR WELDING
THERMAL RESISTANCE:The thermal resistance of FSW modular heat sink is 8% lower than bonded fin design.
*THE DEFINITION OF THERMAL RESISTANCE:
FRICTION STIR WELDING
LIQUID COOLINGTypical Definition: Copper pipes thermally glued to aluminum plate, than vacuum brazedChallenges: Rising price in copper, manual process, lengthy processSapa Solution: FSW cold plates with extruded “pipes”
FRICTION STIR WELDING
METHODThe liquid cooler is sealed by friction stir welding the lids to the extruded body.
FRICTION STIR WELDING
*PATENTED BY SAPA
EXTRUDED LIQUID COOLER*
FRICTION STIR WELDING
69
METALLOGRAPHIC EXAMINATION
PRESSURE TESTThe liquid cooler can withstand burst pressure up to 90 bar.
FRICTION STIR WELDING
LIQUID COOLING: COMPARISON OF TWO DESIGNS
Heat source
30
Heat source
15
199
LIQUID COOLING: TEMPERATURE & FLOWDesign No.2Design No.1
LIQUID COOLER (COLD PLATE) FOR COOLING OF ELECTRONICS IN HEV
Thermal Performance
- Alloy selection- Fin design/spacing- Heat sink orientation- Surface treatment- CFD Analysis
Extrusion Design
- Weight reduction- Profile functionality- Space limitations- Best practice mfg.
Efficient cost
effective solution
SUMMARY OF ALUMINUM EXTRUSIONS & FSW
FRICTION STIR WELDING - CONSISTENTLY ENABLING STRONGER, MORE EFFICIENT STRUCTURES
#DWwebinar
The Advantages of Using Extrusions to Solve Thermal Management Challenges for the Automotive Industry
Stephen Jackson Business Development Mgr., TM ProductsSapa Extrusions [email protected]
Questions?
Mary GannonSenior Editor – ModeratorDesign [email protected]
#DWwebinar
Thank YouThis webinar will be available at designworldonline.com & emailTweet with hashtag #DWwebinarConnect with Design WorldDiscuss this on EngineeringExchange.com
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