Factors that improve thermal performance of aluminium heat sinks

Aluminium heat sinks are usually air-cooled or liquid-cooled. Regardless of whether yours uses liquid or air cooling, the main factors that impact its thermal performance include air or liquid flow and fin/channel design. Other factors to consider in the design phase:

• Surface treatment
• Thermal resistance
• Joining methods
• Materials, including the thermal interface material
• Costs

The most common heat sink materials are aluminium alloys in the 6000-series, primarily the 6060, 6061 and 6063 alloys. The thermal conductivity values of these alloys are solid. Their thermal properties are not as good as those of copper, but an extruded aluminium heat sink weighs about half as much as a copper conductor having the same conductivity, and the aluminium solution does not cost as much, either.