Aluminum Extruded Radiator

Aluminum Extruded Radiator is a passive heat dissipation component that uses high-temperature and high-pressure aluminum extrusion technology to force 6063/6061 aluminum alloy billets (containing 0.2-0.6% silicon and 0.45-0.9% magnesium) through customized molds, forming them into high-density parallel fins, complex flow channels, or irregular structures in one go. Its core advantages lie in high thermal conductivity efficiency (180-220 W/m · K), high molding accuracy (tolerance ± 0.1mm), and lightweight (density 2.7g/cm ³ is only one-third of copper). Combined with anodizing surface treatment technology, it can achieve comprehensive performance of corrosion resistance, easy processing, and high heat dissipation density, and is widely used in fields such as electronic power, new energy vehicles, and industrial equipment.

2、 Core Features

1. Efficient thermal conductivity and structural optimization

Thermal conductivity:

Data: The thermal conductivity of 6063 aluminum alloy is 201 W/m · K (25 ℃), which is 109% higher than that of ADC12 die cast aluminum (96 W/m · K). The thermal diffusion coefficient is 66.8 mm ²/s (ADC12 is 32.4 mm ²/s), and the heat transfer rate is doubled.

Principle: Extrusion process eliminates casting porosity, refines grain size to ASTM grade 5 (grain size ≤ 50 μ m), reduces phonon scattering by 30%, and lowers thermal resistance by 25%.

Structural innovation:

Fin design: Wave shaped fins (peak height 15mm, wave spacing 3mm) are achieved through dual in and dual out molds, which increases the heat dissipation area by 40% compared to straight fins and reduces air flow resistance by 20% (pressure drop from 12Pa to 9.6Pa at the same wind speed).

Channel optimization: The water-cooled plate adopts microchannel spiral channels (channel width 0.8mm, depth 1.2mm, spiral angle 15 °). When the coolant flow rate is 1.2m/s, the convective heat transfer coefficient reaches 12000 W/m ² · K, which is 60% higher than traditional straight channels.

2. Lightweight and mechanical properties

Density advantage:

Data: Density of 2.7g/cm ³, 69.7% lighter than copper heat sink (8.9g/cm ³), suitable for weight sensitive mobile devices such as drones and portable power supplies.

Case: The radiator of the DJI Mavic 3 drone motor is made of 6061-T6 aluminum alloy extruded parts, weighing only 120g, which is 350g lighter than the copper solution and increases the range by 12%.

Mechanical strength:

Data: Yield strength ≥ 240MPa (T6 state), elongation ≥ 8%, impact resistance (Charpy V-notch) 25J/cm ², passed cold and hot impact testing (1000 cycles) at -40 ℃ to 120 ℃ without cracks.

Application: The liquid cooled plate of the new energy vehicle battery pack needs to withstand a vibration acceleration of 15g (for 10 hours), and the aluminum alloy extruded parts have passed the ISO 16750-3 vibration test with a fatigue life of over 100000 times.

3. Corrosion resistance and surface treatment

Anodizing protection:

Data: The thickness of the oxide film is ≥ 15 μ m (military grade can reach 25 μ m), the hardness is HV 300-400 (Vickers hardness), and the salt spray test (ASTM B117) has passed for 1000 hours without corrosion (ordinary spray painting only takes 300 hours).

Advantages: The porosity of the oxide film is less than 5%, and the resistance to neutral salt spray is improved by 20 times after sealing treatment. It is suitable for corrosive environments such as offshore platforms and chemical workshops.

Conductivity inhibition:

Data: Insulation oxide layer resistivity ≥ 10 ¹⁴Ω· cm, breakdown voltage ≥ 500V, solves the risk of short circuit caused by aluminum alloy conductivity, and is suitable for high-voltage electrical cabinet heat dissipation module (voltage 690V AC).

4. Cost effectiveness and mass production capability

Manufacturing cost:

Data: The yield rate of extrusion technology is ≥ 95%, and the cost per piece is reduced by 70% compared to CNC machining and 40% compared to die-casting technology (taking 1kg radiator as an example, the extrusion cost is 8.5, CNC is 28, and die-casting is $14).

Efficiency: The production capacity of a single extruder can reach 3 tons/day (8 hours), and the mold life exceeds 50000 times, suitable for batch orders with an annual output of more than 100000 pieces.

Customization flexibility:

Data: The mold development cycle is 15-20 days (die-casting takes 30-45 days), supporting a cross-sectional complexity of ≤ 8 (complexity coefficient=circumference ²/area), and can meet customized requirements such as fin gradient thickness (0.5-2mm) and irregular cavities (such as hexagonal honeycomb structures).

3、 Typical application scenarios and solutions

1. Thermal management of new energy vehicles

Battery pack liquid cooling plate:

Structure: Double layer microchannel extruded water-cooled plate (channel spacing 2mm, depth 1.5mm), integrated explosion-proof valve installation hole and battery module fixing slot.

Performance: When the coolant flow rate is 8L/min, the temperature difference of the battery pack is ≤ 2 ℃, and the thermal resistance is 0.025 ℃/W, meeting the 200kW fast charging and cooling requirements of Ningde Times NCM811 battery.

Motor controller heat dissipation:

Structure: Copper aluminum composite heat sink (substrate copper layer 1.5mm+fin aluminum layer 8mm), thermal interface adopts nano silver sintering process (contact thermal resistance 0.005 ㎡· K/W).

Case: BYD Han EV drive motor controller, IGBT junction temperature ≤ 150 ℃ at peak power of 200kW, reduced by 15 ℃ compared to pure aluminum solution.

2. 5G communication and data center

Base station RF unit:

Structure: Needle shaped heat sink (needle diameter 1mm, height 25mm, spacing 2.5mm), with nickel plated electromagnetic shielding on the surface.

Performance: Thermal resistance of 0.12 ℃/W at wind speed of 3m/s, compatible with Huawei AAU 5639 (power consumption of 1200W), reducing the volume by 40% compared to traditional heat dissipation solutions.

Server GPU cooling:

Structure: VC temperature equalizing plate+extruded fin composite heat dissipation module (VC thickness 1.2mm, fin height 30mm), with built-in phase change material (PCM) heat absorbing layer.

Case: The Inspur NF5488A5 server is equipped with 8 NVIDIA A100 GPUs. When running at full load, the core temperature is ≤ 80 ℃, and the energy efficiency ratio is improved by 18%.

3. Industrial power supply and new energy

Photovoltaic inverter:

Structure: Corrugated fin heat sink (wave height 12mm, wave spacing 4mm), with laser engraved 0.1mm guide grooves on the surface of the fins.

Performance: Under natural convection conditions, the thermal resistance is 0.3 ℃/W, suitable for the SG320HX inverter of the Sunshine Power Supply (power 320kW), and the IGBT junction temperature fluctuation range is ≤ 5 ℃.

Energy storage system:

Structure: Foldable fin water-cooled plate (unfolded area 2.1 ㎡, folded volume 0.03 m ³), built-in flow rate sensor and pressure balance valve.

Case: Tesla Megapack energy storage system, single cabinet heat dissipation power of 1.2MW, coolant temperature fluctuation ≤ 1 ℃, maintenance cost reduced by 60% during the life cycle.