HDDC process for aluminium heat sinks and liquid cold plates

Aavid Thermalloy has announced its High Density Die Cast (HDDC) heat sinks. These heat sinks are said to offer several advantages over their machined, die cast and extruded counterparts.

They are claimed to offer increased thermal performance and uniform thermal distribution because of the ability of the HDDC process to expand the fin configurations, fin thickness and shapes of the heat sink producing, for example pin fins, oblique or elliptical fins and radial fin arrays. Many of these features cannot be achieved via extrusion or standard die casting techniques. Further, the process is said to allow fins to be formed on thinner and lighter wall electronics housings and enclosures with intricate features and low mass.

Another advantage Aavid say its HDDC process has is that it can produce leak tight complex assemblies. Also, wet surface finishing processes like anodising and electroplating can be done without electrolyte retention in surface porosity. Parts made with Al 6XXX alloys can be CAB or vacuum brazed, to form a 3D perfectly sealed LCP.

Like die-casting, the process should be suitable for high volume production including pre-fabricated inserts of copper, stainless steel or other metals for heat spreading or threaded inserts or fittings for fluid connections.

Tom Austin-Morgan

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