压铸散热器与挤压散热器在散热性能上如何比较？
Die Cast vs. Extruded Heat Sinks: A Thermal Performance Comparison
Overview of Heat Sink Manufacturing Methods
Heat sinks are essential for managing thermal loads in electronic and industrial systems. Two widely used manufacturing processes—die casting and extrusion—offer distinct advantages depending on required geometry, material performance, and production volume. Understanding these differences helps engineers select the most reliable and cost-effective thermal solution for their applications.
Thermal Conductivity and Material Considerations
Die Cast Heat Sinks Die cast heat sinks are typically produced from aluminum alloys such as A360 or A380. These alloys exhibit thermal conductivity in the range of 96–105 W/m·K. While this is lower than extruded materials due to silicon content and potential micro-porosity, die casting enables highly complex geometries and integrated design features—such as multi-directional fins and structural consolidation—that can compensate by improving airflow and increasing effective heat dissipation surface area.
Extruded Heat Sinks Extruded heat sinks are made from high-thermal-conductivity 6000-series aluminum alloys (e.g., 6063 or 6061), which generally achieve 200–210 W/m·K. Their superior thermal transfer makes them ideal for applications requiring maximum conduction efficiency. However, extrusion imposes design limitations—fins must follow linear directions, spacing is constrained, and complex integrated shapes are not feasible without costly secondary operations.
Design Flexibility and Performance Optimization
Die casting supports advanced shapes such as pin-fin arrays, curved fins, and multi-directional profiles—configurations impossible to produce with extrusion. These geometries significantly improve convection and thermal dispersion, allowing die cast heat sinks to deliver strong real-world performance even with lower base thermal conductivity.
Extruded heat sinks remain advantageous when consistent linear heat flow and maximum conductivity are the primary requirements, particularly in open, unobstructed cooling environments.
The following table summarizes the differences:
Feature | Die Cast Heat Sinks | Extruded Heat Sinks |
|---|---|---|
Thermal Conductivity | ~96–105 W/m·K | ~200–210 W/m·K |
Design Flexibility | High (complex, multi-directional features) | Limited (linear, uniform cross-sections) |
Integration Capability | High (mounts, EMI shielding, housing integration) | Low (requires secondary operations) |
Surface Area Efficiency | Excellent (dense pin-fin, curved designs) | Moderate (straight fins, wider spacing) |
Production Volume Fit | Best for medium–high volume production | Suited for lower to medium-volume needs |
Practical Application Considerations
For applications such as enclosed electronics, automotive lighting, LED systems, or high-power modules—where airflow optimization, part consolidation, and mechanical integration are critical— die cast aluminum heat sinks offer superior performance and design freedom.
In contrast, extruded heat sinks with post-machined interfaces may still be the preferred choice when peak thermal conductivity is the primary design driver.
How Neway Enhances Heat Sink Manufacturing
Neway provides full-spectrum support for advanced thermal management components through:
High-precision aluminum die casting for complex thermal structures
Expert tool and die design enabling thin fins and multi-directional features
CNC post-machining for flatness, interface accuracy, and enhanced thermal contact
Anodizing services to improve corrosion resistance and thermal emissivity
With integrated engineering, tooling, casting, and finishing, Neway ensures every heat sink meets demanding thermal, mechanical, and production requirements.
