2. 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
3. Moderator Presenters
Paul Heney
Design World
Mike Tozier
Sapa Extrusions
Americas
Alex Chen, PhD
Sapa Extrusions
Americas
Angel Rosario
Sapa Extrusions
Americas
4. ALUMINUM EXTRUSION DESIGN
AND THE ROLE IT PLAYS IN HIGH
PERFORMANCE COOLING
SOLUTIONS
ANGEL ROSARIO, ALEX CHEN, MIKE TOZIER
4
5. OUTLINE
5
Introduction of Sapa Group
Aluminum Extrusion Design
Thermal Design Considerations
High Performance Cooling Solutions
6. SAPA GROUP
6
Sapa is the world leader in aluminum solutions – a new company that joined the aluminum
extrusion businesses of Sapa and Hydro. Together, we are shaping a lighter future through
a global reach and local presence within extrusions, building systems, and precision tubing.
We have 23,000 employees in more than 40 countries, and our headquarters are located in
Oslo, Norway.
7. SAPA EXTRUSIONS AMERICAS
7
Sapa Extrusions North America offers design, manufacturing, fabrication and finishing of
aluminum extrusions through 25 facilities located across North America.
8. PROFILE DESIGN
8
What 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.
9. TOOLING COST FACTORS
Die Breakage
Alloy
Profile type and circle size
Non-fill condition
Thin walls or sharp corners
Thick to Thin Ratio (variable bearings)
Tolerance requirements
9
10. PRODUCT DESIGN COST FACTORS
Type of Profile
Solid
Semi-Hollow
Hollow
Alloy / Temper
6063 vs. 6061
Wall Thickness
Thin? Thin to Thick?
Tolerances
Standard AA vs. Tighter
Cut Length
Long Lengths vs. Short Lengths
Surface Finish
Anodize? Paint?
10
11. PROFILE CLASSIFICATIONS
Solid
Low production cost
Low die cost
Semi-Hollow
Tooling could break sooner
Higher material and die cost
Hollow
Higher Material and Tooling Cost
Multi-Void hollows have the highest cost
11
13. PROFILE CIRCLE SIZE
Not all presses with the same container
size are alike.
For example, Sapa has a number of 10”
presses, but profiles that fit one 10” press
may not fit another 10” press at a different
location.
Circle size is one of the factors for
determining the appropriate size press a
given profile.
Sapa is able to extrude profiles with
circle sizes up to 22” in North America.
13
14. MINIMUM WALL THICKNESS
Recommended minimum wall
thickness for 6063 Alloy are shown in
the guidelines. (Add 15% for 6061
Alloy)
Sapa also offers specialty extrusions
up to 5” diameter circle size with wall
thickness as thin as 0.015” and as
light as 0.007 pounds per foot.
4”
5”
6”
7”
8”
9”
10”
11”
3”
2”
0.052”
14
Guidelines
19. ALUMINUM USED IN COOLING SOLUTIONS
19
Aluminum heat sinks and liquid coolers have been widely used as
cooling components in power electronics, LED lighting, computers,
telecom devices, healthcare, automotive, etc.
20. ALUMINUM EXTRUSIONS
20
Recyclable & Non-toxic
Lightweight
Strong
Corrosion resistant
Thermally conductive
Reflective
Electrically conductive
Non-magnetic
Non-sparking
Material Advantages
Attractive
Finish Options
Virtually Seamless
Complex integral shapes
Easily assembled
Weldable
Machinable
Cost-effective
Short lead times
Process Advantages
31. SIMULATION
31
Critical items needed for design support:
Max junction temp (Tj) or thermal resistivity requirements
Ambient temperature and boundary conditions
Heat sink orientation relative to gravity
Heat load definition and placement (Watts)
CAD assembly detailing heat sink and mating components with
material definitions (SolidWorks or .stp file)
Re-design space limitations / requirements
32. FRICTION STIR WELDING
32
Friction Stir Welding is a solid-state joining method, which has been used
in the welding of aluminum since 1991.
35. ADVANTAGES OF FRICTION STIR WELDING
35
No filler metal (parent metal conductivity)
High tensile, fatigue, and bend properties
Void free and leak proof
Low thermal distortion and shrinkage
Energy efficient
Suitable for automation
Cost Effective
50. Questions?
Paul Heney
Design World
pheney@wtwhmedia.com
Phone: 440-234-4531
Twitter: @DW_Editor
Mike Tozier
Sapa Extrusions Americas
Mike.Tozier@sapagroup.com
Phone: 503-802-3462
Alex Chen, PhD
Sapa Extrusions Americas
Alex.Chen@sapagroup.com
Phone: 801-450-7221
Angel Rosario
Sapa Extrusions Americas
Angel.Rosario@sapagroup.com
Phone: 847-349-7244
51. Thank You
This webinar will be available at
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