High Thermal Conductivity Die-Cast Heat Sinks design manual

Aluminum alloy die-cast housing is a key part of inverter energy storage new energy/telecom/lighting etc, જે સુરક્ષા સ્તર પ્રદાન કરે છે, ગરમીનું વિસર્જન પ્રદર્શન અને સૌંદર્યલક્ષી આવશ્યકતાઓ. ડાઇ-કાસ્ટ હાઉસિંગ ડિઝાઇનનો મૂળ સિદ્ધાંત એ છે કે તેના ગેરફાયદાને ટાળતી વખતે અથવા ઘટાડતી વખતે ડાઇ-કાસ્ટિંગ પ્રક્રિયાના ફાયદાઓનો સંપૂર્ણ ઉપયોગ કરવો.

The advantages of die casting process નીચે મુજબ છે:

1. ઉચ્ચ ઉત્પાદન કાર્યક્ષમતા: ડાઇ કાસ્ટિંગ પ્રક્રિયામાં, the metal liquid is filled into the mold cavity under high pressure and high speed, and then can obtain parts with complex shape and accurate size after cooling.
2. Low production cost: compared with other casting processes, die-casting has lower energy consumption and relatively low production cost.
3. Short production cycle: in the die-casting production process, the metal liquid is filled into the mold cavity under high temperature and pressure, and the parts can be obtained after cooling, so the production cycle is relatively short.
4. Fast technological progress: With the continuous progress of die-casting technology, the precision, efficiency and quality of die-casting production are constantly improving, and the integrated die-casting of Tesla reduces the assembly of parts.

The disadvantages of die casting process નીચે મુજબ છે:

Die casting is an efficient method of metal forming, but it also has some disadvantages and limitations. The following are some of the main disadvantages of die casting:

High cost: Die casting requires the manufacture of die casting molds with high manufacturing costs, especially for complex geometries and small batch production, where mold costs can be expensive.

Design constraints: Die casting process has certain limitations on the design of castings, such as the uniformity of wall thickness and the formability of shape, otherwise it may lead to poor quality or production difficulties.

Surface defects: due to the rapid cooling process, die-cast parts may have defects such as pores, shrinkage holes and slag inclusions on the surface, which affect the surface quality.

Material limitations: Die casting is usually suitable for low melting point alloys and certain specific metals. For high melting point materials or some chemically special materials, die casting may not be suitable.

Assembly requirements: Due to the shrinkage rate of die-cast parts, post-processing and assembly are sometimes required to meet precise size requirements.

 

તેથી, the following principles should be followed in die casting design:

 

Reasonable Geometric Shapes: When designing, the characteristics of die casting should be considered to avoid overly complex or difficult-to-form geometric shapes. Simplified and symmetrical designs are preferred to reduce costs and production difficulty. Sharp corners and protruding features should be avoided as much as possible to minimize stress concentration and deformation in the casting. Rounded corners and fillets should be used whenever feasible to enhance the strength and durability of the casting.

Wall thickness uniformity: maintain the wall thickness of die-cast parts to avoid excessive or slow solidification rate, resulting in casting quality problems.

Ejection Angle: Ensure that enough ejection Angle is included in the design so that the casting can be removed smoothly without damage or defects.

Reasonable fitting and edge design: ensure the rationality of fittings and edges to avoid excessive cutting and post-processing

Material selection: According to the application requirements and performance requirements, select appropriate materials, considering factors such as material fluidity, shrinkage rate and mechanical properties.

Manufacturability, design reliability: in the design process, the production process and process requirements should be fully considered to ensure that the design is achievable and producible.

Selection of High Thermal Conductivity Die-Cast Heat Sinks

The selection of die-casting alloy materials should be comprehensively considered based on the functional requirements, process requirements, and economic considerations of the part. Different types of alloy materials have different characteristics and application ranges. સામાન્ય રીતે કહીએ તો, the new energy industry primarily uses aluminum alloys, which offer high strength, stiffness, પ્રતિકાર પહેરો, and corrosion resistance, making them suitable for high-demand structural and mechanical components. Below are the commonly used die-casting aluminum alloy materials and their main properties:

Type of alloy	ઘનતા (g/cm3)	melting point (℃)	તણાવ શક્તિ (MPa)	વિસ્તરણ (%)	કઠિનતા (એચબી)	થર્મલ વાહકતા (W/m·K)	corrosion resistance
alu Conventional ADC12	2.68	515-582	310	2.5	75	91	secondary
alu ENAC44300/ALSI12(FE)	2.68	515-582	155	2	50	150	good
alu DC01R2	2.68	515-582	170	2	55	155	good

Determination of wall thickness of die casting

The determination of the wall thickness of die-cast parts should take into account the functional requirements, process requirements, and economic considerations. સામાન્ય રીતે કહીએ તો, the wall thickness of die-cast parts should be as uniform as possible, avoiding both excessive thickness and thinness. An excessively thick wall can lead to difficulties in filling, uneven shrinkage, increased porosity, and higher costs; an excessively thin wall can result in incomplete filling, insufficient strength, and increased deformation. તેથી, the wall thickness of die-cast parts should be determined based on the following factors:

• Flowability and shrinkage of alloy materials
• Shape and size of parts
• The stress condition and safety factor of the part
• Heat treatment and surface treatment of parts
• Part accuracy and surface quality
• Batch size and cost of parts

The following are the commonly used die-cast alloy materials and their recommended minimum wall thickness:

	minimum wall thickness (મીમી)		Medium aluminum alloy wall thickness	Thickest wall
ડાઇ-કાસ્ટિંગ એલ્યુમિનિયમ	1.0		3એમએમ	8એમએમ

Of course, these are only general reference values, and the specific wall thickness should be determined according to the actual situation of the part. In the design, the wall thickness of each part of the part should be as close as possible. If necessary, the wall thickness can be reduced by using ribs to strengthen the structural strength and weight of the product.

Die casting parting surface and internal and external angles, draft design

The parting line of a die-cast part is the surface on which the part separates in the mold. It directly affects the manufacture and use of the mold. સામાન્ય રીતે, the parting line of a die-cast part should be as simple, straight, and few as possible, and perpendicular or parallel to the main axis of the part. This reduces the machining of the mold

• Processing difficulty, improve the strength and stiffness of the mold, avoid deformation and damage of the mold
• Reduce the burr and deformation of parts, improve the accuracy and surface quality of parts, reduce the post-processing process of parts
• Reduce the part filling resistance, improve the part filling and filling rate, reduce the defect and scrap rate of parts

The internal and external corners of a die-cast part refer to the edges and corners on the parting line or other areas; they also affect the manufacture and use of the mold. સામાન્ય રીતે, the internal and external corners of a die-cast part should be as small, smooth, and uniform as possible, and perpendicular or parallel to the parting line. This can:

• Reduce the processing difficulty of the mold, improve the wear resistance and impact resistance of the mold, prolong the service life of the mold
• Reduce the stress concentration of parts, improve the strength and stiffness of parts, avoid part fracture and deformation
• Reduce burrs and pores of parts, improve the surface quality and internal quality of parts, reduce the post-processing process of parts

The following are the commonly used die-casting alloy materials and their recommended minimum inner and outer corner radii:

Type of alloy	Ejection Angle	Minimum inner corner radius (મીમી)	Minimum outer corner radius (મીમી)
alufer	1°～3°	0.5	0.3

 

thermal design:

The transformer will generate a lot of heat in the process of working, so the heat dissipation design is very important. The shell should be designed with ventilation slots, so that the air can circulate and help heat dissipation.

 

 

 

The size of the right figure is mm, which is difficult to die-cast. It is recommended not to use it if the heat dissipation requirement is not high. જોકે, Songyuxing still has the ability to produce it, but the cost is higher.

The normal size height is about 60mm, the demolding is 2° to 3° and the top thickness is 1.5mm. If you need to enhance the heat dissipation performance, you can use ALsi 12 or DC01

તે જ સમયે, it is suggested that the larger the chamfer on the side of the tendon, the better. The same slope is more conducive to forming and reducing the difficulty of production. As shown in the figure below

Safety, beauty, dustproof and waterproof design:

 

The die-cast housing should have a certain safety, such as the design of anti-electrocution, anti-misoperation and other safety measures. When designing the inverter die-cast housing, the convenience of installation and maintenance should be considered. દાખ્લા તરીકે, appropriate installation holes and screw holes should be provided for easy installation and maintenance.

The dustproof and waterproof design of the die-cast inverter housing can be achieved using sealing strips or potting technology. This primarily ensures that the housing meets a certain IP rating, which indicates its protection against solid foreign objects and water. The IP rating consists of two digits: the first digit represents the dustproof rating, and the second digit represents the waterproof rating. The higher the number, the stronger the protection. દાખ્લા તરીકે, IP68 indicates complete protection against dust ingress and the ability to withstand prolonged submersion in water under certain pressure without damaging the equipment

 

The inverter die-cast housing should have a certain level of aesthetics, which can be enhanced through surface treatment and color coordination to improve the overall appearance of the product. Surface treatment of die-cast parts involves cleaning, પોલિશિંગ, પેઇન્ટિંગ, and plating operations to improve or adjust the appearance and performance of the parts. સામાન્ય રીતે, surface treatment of die-cast parts can enhance their glossiness, color intensity, smoothness, પ્રતિકાર પહેરો, and corrosion resistance, as well as increase or decrease the friction coefficient, electrical conductivity, and magnetic permeability of the parts. Different types of alloy materials have different surface treatment methods and effects. Below are commonly used die-cast alloy materials and their primary surface treatment methods:

Type of alloy	Main surface treatment methods
alu	Powder spraying (if corrosion resistance is required, it is recommended to add oxidation or electrophoresis process)

 

As a leader in die casting China, SYX provides cutting-edge die-casting solutions for heat sink designs, leveraging years of expertise to produce efficient and cost-effective thermal management products. Die casting Manufacturer China offers world-class manufacturing capabilities, allowing companies to access high-quality die-cast heat sinks at competitive prices.