Die Cast Aluminum VS Aluminum Extrusion Heat Sink

The versatility of aluminum today is extensive. Many manufacturing processes are used to work the material into different variations.

Two of the prominent ones are its casting and extrusion. Both methods have their advantages and disadvantages. This makes them also valuable for making heat sinks.

You might be looking for producing your heat sink but you are unsure which method will serve you the best. It can not be said which way is best for your heat sink over the other because one might perform better in one condition where the other is lagging.

But don't worry; this article has everything you need to know about extrusion and die-casting aluminum heat sinks. By the end of this, you will know which one suits you the most.

Let's get started:

Introduction

What is die cast aluminum?

Die cast aluminum is a method where the molten aluminum is filled into a die cast mold of the required shape and allowed to cool, then removed.

Various methods are used to cast aluminum material, such as plaster casting, continuous casting, sand casting, and die casting.

The main benefit of die casting aluminum is that it can have very strong parts while still keeping the weight low. And also other benefits like high conductivity and recyclability.

What is Aluminum Extrusion?

This process involves heating and shoving aluminum billets into an open die shape. Different designs and sizes are made by diversifying the shape die opening.

Similarly, they are adamant because of their lightness, at the same time, being very strong. Other benefits include impeccable surface finishing and some complex geometrical possession.

Now let us look at what it means for the two methods to be applied in Heat sink production and when they will serve the most and where they are best applicable.

What is die cast aluminum heat sink？

Die cast aluminum heat sink is the equipment used in electronics to drive out or absorb heat and cool the device(heat sink) made from the aluminum die casting method.

The die cast aluminum process allows complex production, which helps to create a heat sink that does not need additional resistance, will absorb heat, and send it out to the environment directly. This, among plenty other factors we will explain in a short while, and the significant values it brings to heat sinks.

The aluminum die cast heat is applicable in so many areas, such as:

       ● Sheets or layers of Personal computers(PC)

       ● LED coverings or sheets

       ● Highly powered lasers

       ● Fixtures

       ● Lodgings

       ● Communication devices(mobile phones)

       ● Audio hardware

       ● Automotive hardware

What Is an extrusion aluminum heat sink？

In the same vein, the heat sink( heat absorbing mechanism in electronic devices) produced as a result of the extrusion of aluminum is an aluminum extrusion heat sink.

One prominent advantage of using this method for the heat sink is its lightweight, among others.

Here are the applications below:

       ● Transaction drives

       ● Motor housing controller

       ● Electrical devices

       ● Telecommunication drives

       ● Aerospace engineering

Extrusion aluminum heat sink or die cast aluminum heat sink?

To make this selection narrower and easier to pick from, let's look at the advantages and disadvantages of the Extrusion aluminum heat sink and Die cast aluminum heat sink below.

Advantages of the extruded aluminum heat sink.

Aluminum material itself has notable characteristics of lightweight and availability characteristics. As well, it is easy to make complex parts. This adds to the die cast heat sink produced and some other benefits too. Such as:

       ● Cost-effective: The method can be cost-effective as the materials are very easy to get and eventually less expensive to purchase. But not necessarily cheap to produce.

       ● Highly safe: The extruded aluminum heat sink is a powerful part in times of withstanding shock and pressure. When it is being installed or handled, it is less likely to damage.

       ● Flexibility: The heat sink can be machined by various welding methods, possess any type of fin required by the manufacturer, and come in a wide range of colors. It has an excellent surface area.

       ● Very versatile: Aluminum extruded heat sink is adaptable for many mediums. It can be used as conducting material or as a chip in an electronic device.

       ● Highly resistant to corrosion: In the presence of weather fluid or air medium, the extruded aluminum heat sink will last a very long time. Evidence of the thick surface film and solid oxide.  

       ● Lightweight: As mentioned above, the aluminum material by itself is light. This makes the extruded aluminum heat sink relatively light and straightforward to induct. This serves as the go-to option for little or convenient electronic devices.

       ● Less use of energy: It is a simple method for making heat sinks and so takes up a considerably low amount of power.

Disadvantages of the extruded aluminum heat sink.

Even with all the significant pros, there are specific barriers that should be taken into consideration.

       ● The produced heat sink does dissipate heat like other materials. It does it at a lower rate.

       ● It is somewhat of a puzzle that aluminum extrusion heat sinks are more expensive to purchase even though the materials are easy to get. This is because the after-machining costs a lot.

       ● They can be damaged easily, and they are not durable as other materials.

       ● Also, they can be challenging to install sometimes.

Advantages of die cast aluminum heat sink.

       ● Conduct electricity:  Die cast aluminum heat sink can be used in electricity situations without any copper coating needed.

       ● The secondary machining operation and assembly are not needed here as the parts are made with a rugged surface finishing that does not need them.

       ● High thermal conductivity: They can dissipate heat very effectively.

       ● Flexibility: Die cast aluminum heat sink can be produced with ease and shaped to different required sizes and designs.

       ● Longevity: The heat sinks can last a long time because they are very durable and resistant to corrosion. Also, because of their excellent surface finishing, they can be polished for further prevention.

Disadvantages of die cast aluminum heat sink

See the several cons of Die cast aluminum heat sink below:

       ● They are not very good in times of withstanding impact or pressure with a minimal strength-to-weight ratio.

       ● It is expensive and time-consuming to produce.

       ● It is not recommended for large volume production.

       ● The process of manufacturing this heat sink requires skilled labor conditions.

In Conclusion: Which Heatsink Is Right For You?.

Basically, the two methods, the Extrusion aluminum and Die cast method for making heat sinks, share a lot of similarities. One significant difference is in their manufacturing process.

To decide the best for your business, you need to compare the two methods and your business purpose. With the information above, you can find their area of strength and if your service falls under a category.

However, if you still need the best advice in a detailed and complete form, specifically given to you to tackle your precise needs, our personnel at Winshare Thermal are in your best interest.

Constantly serving the International community for more than 30 years, any advice you need will be m provided richly.

If you require a Die cast or Extrusion aluminum heat sink produced in a speedy turnaround time, contact us now.