thermal solutions – based on numd · 2019-03-18 · thermal solutions. local presence – global...
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45 ~– Based on Aluminium Extrusions
Thermal Solutions
Local presence – global competence
Sapa invites you to take a look at our world of
cooling solutions by utilizing and combining our
expertise with the unique properties of intelligent
aluminium extrusion and, if you like what you see,
to take the next step by entering into a partner-
ship with Sapa.
• Sapa has 14,000 employees in 35 countries
and sales of USD 5 billion/EUR 3.8 billion
• As the world’s largest provider of extruded
aluminium profiles, Sapa is a leading supplier
to all sectors using aluminium as the strategic
material: transportation, general engineering,
solar, telecom, renewable energy, and more...
• As part of our global centres of excellence,
we have specialists in the area of thermal
management with in-depth knowledge of
manufacturing, product design, prototyping,
testing and analysis, and project management.
We aim to become your preferred supplier of
extruded aluminium cooling solutions.
You are also welcome to visit our website
www.sapagroup.com, or contact our team:
Intelligent aluminium
profile solutions
Aluminium Profiles: we make them simple or advanced, big or small, direct or indirect – and with high aspect ratios.
We deliver profiles from over 100 extrusion presses, from as small as 5
mm (0.20") and 30 g/m (0.020 lb/ft) to profiles up to 620 mm (24.0")
and 65 kg/m (43.7 lb/ft).
Add to that our technical expertise:
• R&D Technology Centre, design support
• Testing and FEM of structural profiles and components
Endless opportunitiesIt is possible to integrate a wide range of functions into an extruded
aluminium profile. Sapa’s “idea profile” (picture on the right) illustrates
some examples: e.g. heat sinks, integral tubes, hinges, latches, screw
ports, decorative patterns, slots for screws, rivets or rubber seals, lugs,
etc.
Built-in profile features reduce your manufacturing costs and enhance
functionality. Do not hesitate to exploit our wealth of experience from
millions of profile designs.
Extruded aluminium profiles – the perfect starting point for developing customized cooling solutions
Our competencies and production capabilities make us a
major supplier across broad sectors like renewable energy,
transportation and general engineering, and in specialized
industries like LED lighting, power conversion, telecom and
medical equipment.
Features like thermal conductivity, strength, ductility,
corrosion resistance combined with low weight and the
cost-saving potential of integrating intelligent features into
the profile are unique and comprise important tools in our
Thermal Management toolbox. At the same time, we can
help you to choose the right alloy that meets the require-
ments in the manufacturing of your final cooling solution.
Thermal conductivity:
• pure aluminium: 230 W/(m∙K) (difficult to machine)
• extruded alloy 6063 HC (T6, T61): 200–215 W/(m∙K)
• cast alloys: 120–140 W/(m∙K)
• copper (pure): 390 W/(m∙K) (much heavier and more
expensive)
Quick guide to selecting an alloy – if in doubt ask Sapa for advice
With 3 being the highest score in the ranking
Get started with your own profile design
Thermal analysis and product simulationAllowing our experts to propose an idea for your first hesitant beginnings of a new heat sink
design results in a clear picture. This identifies the potential improvement from using advanced
thermal analysis and complex product simulations using FEA (linear static), fluid dynamics, assembly/
tolerance analysis or snap-fit design. With these services we can identify further options for:
• reducing material content,
• delivering optimized sections,
• proposing simplified assembly and bringing you even more fabrication options.
“40%” better cooling performance and “30%” weight reduction. Innovative and cost-effective solutions
are all about knowing how to optimize component design. At Sapa we combine our extrusion
experience with Computational Fluid Dynamics (CFD) and other advanced simulation techniques.
Thermal conductivities
Ther
mal
con
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iviti
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/mk
Pure aluminium
250
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0Extrude al-alloys Cast al-alloys
Tensile strength
Impact toughness
Surface finish
Suitability fordecorative anodizing
Corrosion resistance
Machinability:
cutting
plastic forming
Weldability
Thermal conductivity
Electrical conductivity
Price
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Sapa6060
Sapa6063
Sapa6005
Sapa6082
Sapa1050A
Sapa6101
Sapa6463
For electricalconductors
Characteristicproperties
Alloys
For brightanodizing
We add value to your heat sink solutions– and help you to enhance your performance
We are experts in aluminium design and
extrusion technology. Add to that our
world-wide technology centres comprising
specialists within engineering, marketing,
machining and product design. They are the
ones who understand your industry and can
make your innovations become a reality. In the
heat-sink industry we know from experience
that improved thermal performance using
aluminium extrusions often leads to
• longer service life
• higher efficiency
• lower overall system costs
… to liquid coolers with Friction Stir Welding technology
The unique possibilities of Friction Stir Welding
enable us to produce liquid coolers with
outstanding performance. Liquid coolers can be
designed with lower weight, lower total costs
and, in many cases, improved heat-transfer
performance. The joints can be made to be
very flexible, because no filler metal is used in
the FSW process, while high conductivity and
strength are maintained at the joint line. One of
our liquid cooling designs has been success-
fully lab-tested in over 5,000,000 leak-proof
cycles.
Sapa has the resources to not only design,
but also to simulate and test new liquid cooler
concepts.
Special Cooling solutionsThere may be regional variances in our capabili-
ties, contact your regional Sapa office with your
specific enquiry.
Embedded heat pipes
Using embedded heat pipes spreads the heat
more uniformly over the heat-sink base. A heat
pipe is a passive device with highly effective
thermal
conductivity. The heat pipe can be bent or
flattened before soldering/bonding, which extracts
heat from a device very rapidly and bonds it to
the bent aluminium heat-sink base.
Embedding heat pipes into heat sinks by solder-
ing improves thermal performance compared to
the original extruded heat sink shown below.
Copper padsTake advantage of highly conductive copper, without increasing the weight or the cost!
Aluminium heat-sink performance can be
improved by integrating copper pads into the
base, by either soldering or Friction Stir
Welding. Copper’s excellent heat-transfer
properties are used to reduce the temperature
in high-load areas.
Sapa has the resources not only to design, but also to simulate and test a new liquid cooler concept.
Don’t just dream of sophisticated fabrication – ask for it..!
Sapa operates a global network of
manufacturing facilities. We offer our
customers a broad range of fabrication,
from advanced CNC machining to
traditional tooling like cutting, punching,
milling, drilling, etc. Sapa is a global leader
in Friction Stir Welding but we have also
access to traditional welding and other
joining technologies.
Surface treatment – design and function – capsule and componentIn many business areas, the surface of our
extruded aluminium solutions is an integral
part of the design. But we also offer various
surface treatments if additional coatings
and protection are required.
For your heat-sink components we offer
clear anodized surface treatment according
to Osa, 1,3o C/W3” - 0.67 o F/W75mm and
black anodized surface treatment
according to Osa 1.0o C/W/3” - 0.60
F/W/75mm.
Customized seminars produce customized solutions!A partnership with Sapa is your passport
to our world of R&D expertise in aluminium
and our global network of production sites.
Let Sapa conduct your next technical
in-house seminar and tailor a team of
specialists who know your industry.
We can cover anything from basic
materials science, profile design,
analysis tools, simulation, machining,
anodizing and more.
Vendor Managed Inventory – another important link in your future value chain
Sapa has the global power and presence to further improve your supply chain performance.
With our VMI model we are responsible for creating and maintaining your inventory plan regardless
of where you need your components.
Bright light for a green sectorLED lighting might not be a novelty anymore. But the breadth of its fields of application
certainly is. The luminaries of Fionia Lightning – a research company related to the
University of Southern Denmark – are a shining example. After five years of R&D, Fionia
launched its LED-lighting fixtures that will save up to 40% of the energy required by
conventional lighting systems.
High fin density heat sinks
Aspect ratios up to 30:1 or more are possible using
Sapa’s pressed fin solution in combination with Friction Stir
Welding. Low contact resistance in the base due to joint
configuration enables a high flow of heat. Customized fin
spacing, thickness, and lengths to meet pressure-drop
requirements and optimized surface areas are also pos-
sible.
Standard heat sink solutionsAt some of our locations, we offer our customers a range of standard extruded heat sinks for various
applications
• inverters
• telecom
• LED
• drives
• medical equipment.
Contact your local Sapa sales representative to hear more.
