Abstract
As a result of the rise in processing power demands of today’s personal computers, water-cooled pin fin heat sinks are increasingly being employed for the cooling of graphical processing units. Currently, these high-performance devices are manufactured through high-cost, high-waste processes. In recent years, a new solution has emerged using the cold gas dynamic spray process, in which pin fins are manufactured onto a base plate by spraying metallic powder particles through a mask allowing for a high degree of adaptability to different graphics processing unit shapes and sizes. One drawback of this process is reduced deposition efficiency, resulting in a fair portion of the feedstock powder being wasted as substrate sensitivity to heat and mechanical residual stresses requires the use of reduced spray parameters. This work aims to demonstrate the feasibility of using powder recycling to mitigate this issue and compares coatings sprayed with reclaimed powder to their counterparts sprayed with as-received powder. The work demonstrates that cold gas dynamic spray is a highly flexible and economically competitive process for the production of pin fin heat sinks when using powder recycling. The heat transfer properties of the resulting fins are briefly addressed and demonstrated.
Similar content being viewed by others
Abbreviations
- ΔT 1 :
-
Inlet temperature difference (°C)
- ΔT 2 :
-
Outlet temperature difference (°C)
- ΔT lm :
-
Log-mean temperature difference (°C)
- η f :
-
Fin efficiency
- η o :
-
Surface efficiency
- θ :
-
Fin base angle (°)
- μ :
-
Dynamic viscosity (Pa s)
- ρ :
-
Density (kg/m3)
- A*:
-
Nozzle throat area (m2)
- A fin :
-
Fin area (m2)
- A tot :
-
Total heat transfer area (m2)
- A un-fin :
-
Un-finned area (m2)
- B :
-
Transverse fin base width (m)
- B s :
-
Side fin base width (m)
- C Cu :
-
Cost of copper ($/kg)
- C electricity :
-
Cost of electricity ($/kW-h)
- C labor :
-
Cost of labor ($/h)
- C N2 :
-
Cost of nitrogen ($/kg)
- Cp N2 :
-
Specific heat of nitrogen (kJ/kg K)
- D :
-
Linear spray distance (m)
- D h :
-
Hydraulic diameter (m)
- DEmask :
-
Mask deposition efficiency
- DEsubstrate :
-
Substrate deposition efficiency
- EC:
-
Total electricity cost ($)
- GC:
-
Total gas cost ($)
- H :
-
Fin height (m)
- h :
-
Convection coefficient (W/m2 K)
- I 1 :
-
First-order modified Bessel function
- I 2 :
-
Second-order modified Bessel function
- k :
-
Specific heat ratio
- k Cu :
-
Conductivity of copper (W/m K)
- L :
-
Length of the finned area (m)
- LC:
-
Total labor cost ($)
- m :
-
Fin parameter (m−1)
- \(\dot{m}_{{N}2}\) :
-
Mass flowrate of nitrogen (kg/s)
- \(\dot{m}_{{\rm water}}\) :
-
Mass flowrate of water (kg/s)
- N fins,w :
-
Number of fins widthwise
- P*:
-
Pressure at the nozzle throat (Pa)
- P flow :
-
Perimeter of the flow area (m)
- P o :
-
Stagnation pressure (Pa)
- PC:
-
Total powder cost ($)
- PCmask :
-
Total powder cost lost on the mask ($)
- PCsubstrate :
-
Total powder cost lost on the substrate ($)
- PCun-deposited :
-
Total powder cost un-deposited ($)
- PFR:
-
Powder feed rate (kg/s)
- \(\dot{Q}_{\text{Cu}}\) :
-
Heat rate through copper (W)
- Q N2 :
-
Total heat into nitrogen (J)
- \(\dot{Q}_{N2}\) :
-
Heat rate into nitrogen (W)
- \(\dot{Q}_{\text{water}}\) :
-
Heat rate into water (W)
- R :
-
Ideal gas constant (J/mol-K)
- R Cu :
-
Resistance of copper (K/W)
- R eq :
-
Equivalent resistance (K/W)
- R fin :
-
Resistance of fins (K/W)
- R TC :
-
Thermal contact resistance (K/W)
- R un-fin :
-
Resistance of un-finned area (K/W)
- Re :
-
Reynolds number
- S :
-
Distance between fins (m)
- t :
-
Time of spray (s)
- T*:
-
Temperature at nozzle throat (°C)
- T 1 :
-
Inlet temperature of nitrogen (°C)
- T 2 :
-
Outlet temperature of nitrogen (°C)
- T block :
-
Temperature of the block (°C)
- T o :
-
Stagnation temperature (°C)
- T s :
-
Surface temperature (°C)
- T water,in :
-
Water inlet temperature (°C)
- T water,out :
-
Water outlet temperature (°C)
- UA:
-
Thermal conductance (W/K)
- V max :
-
Maximum flow velocity (m/s)
- V T :
-
Traverse velocity (m/s)
- W :
-
Width of the finned area (m)
References
D. Kanter, Graphics Processing Requirements for Enabling Immersive Vr, AMD Dev. Whitepaper, 2015, p 1–12. http://developer.amd.com/wordpress/media/2012/10/gr_proc_req_for_enabling_immer_VR.pdf. Accessed 1 Feb 2018
W. Nakayama, Evolution of Hardware Morphology of Large-Scale Computers and the Trend of Space Allocation for Thermal Management, J. Electron. Pack., 2016, 139, p 010801–1-010801-22
S.A. Jajja, W. Ali, H.M. Ali, and A.M. Ali, Water Cooled Minichannel Heat Sinks for Microprocessor Cooling: Effect of Fin Spacing, Appl. Therm. Eng., 2014, 64, p 76-82
K. Azar and B. Tavassoli, Choosing and Fabricating a Heat Sink Design, Qpedia Thermal Manag. Electron. Cool. Book, 2008, 2, p 173-177
NVIDIA, NVIDIA GeForce GPU’s. https://www.geforce.com/hardware/desktop-gpus. Accessed 5 Jan 2017
AMD, AMD GPU Products. https://gaming.radeon.com/en/category/products/. Accessed 5 Jan 2018
M.F. Ashby, Materials Selection in Mechanical Design, 3rd ed., Elsevier, Oxford, 2005, p 197-209
R.N. Raoelison, C. Verdy, and H. Liao, Cold Gas Dynamic Spray Additive Manufacturing Today: Deposit Possibilities, Technological Solutions and Viable Applications, Mater. Des., 2017, 133, p 266-287
A. Sova, S. Grigoriev, A. Okunkova, and I. Smurov, Potential of Cold Gas Dynamic Spray as Additive Manufacturing Technology, Int. J. Adv. Manuf. Technol., 2013, 69, p 2269-2278
P. Dupuis, Y. Cormier, M. Fenech, and B. Jodoin, Heat Transfer and Flow Structure Characterization for Pin Fins Produced by Cold Spray Additive Manufacturing, Int. J. Heat Mass Transf., 2016, 98, p 650-661
P. Dupuis, Y. Cormier, A. Farjam, B. Jodoin, and A. Corbeil, Performance Evaluation of Near-Net Pyramidal Shaped Fin Arrays Manufactured by Cold Spray, Int. J. Heat Mass Transf., 2014, 69, p 34-43
Y. Cormier, P. Dupuis, A. Farjam, A. Corbeil, and B. Jodoin, Additive Manufacturing of Pyramidal Pin Fins: Height and Fin Density Effects under Forced Convection, Int. J. Heat Mass Transf., 2014, 75, p 235-244
H. Mäkinen, J. Lagerbom, and P. Vuoristo, Adhesion of cold sprayed coatings : effect of powder, substrate, and heat treatment, Thermal Spray 2007: Global Coating Solutions, B.R. Marple, M.M. Hyland, Y.-C. Lau, C.-J. Li, R.S. Lima, and G. Montavon, Ed., Springer, Beijing, 2007, p 31-36
P. Sudharshan, D.S. Rao, S.V. Joshi, and G. Sundararajan, Effect of Process Parameters and Heat Treatments on Properties of Cold Sprayed Copper Coatings, J. Therm. Spray Technol., 2007, 16(3), p 425-434
K.L. Chavez and D.W. Hess, A Novel Method of Etching Copper Oxide Using Acetic Acid, J. Electrochem. Soc., 2001, 148(11), p 640-643
P.J. Pritchard and J.C. Leylegian, Introduction to Fluid Mechanics, 6th ed., Wiley, New York, 2011
C. Borgnakke and R.E. Sonntag, Fundamentals of Thermodynamics, 8th ed., Wiley, New York, 2013
F.P. Incropera, T.L. Bergman, A.S. Lavine, and D.P. DeWitt, Fundamentals of Heat and Mass Transfer, 7th ed., Wiley, New York, 2011
Y. Cormier, P. Dupuis, B. Jodoin, and A. Corbeil, Net Shape Fins for Compact Heat Exchanger Produced by Cold Spray, J. Therm. Spray Technol., 2013, 22(7), p 1210-1221
D.D.L. Chung, Materials for Thermal Conduction, Appl. Therm. Eng., 2001, 21(16), p 1593-1605
K. Binder, J. Gottschalk, M. Kollenda, F. Gärtner, and T. Klassen, Influence of Impact Angle and Gas Temperature on Mechanical Properties of Titanium Cold Spray Deposits, J. Therm. Spray Technol., 2011, 20(1–2), p 234-242
J. Wu, H. Fang, S. Yoon, H. Kim, and C. Lee, The Rebound Phenomenon in Kinetic Spraying Deposition, Scr. Mater., 2006, 54, p 665-669
M. Fukumoto, M. Mashiko, M. Yamada, and E. Yamaguchi, Deposition Behavior of Copper Fine Particles onto Flat Substrate Surface in Cold Spraying, J. Therm. Spray Technol., 2010, 19(1–2), p 89-94
B. Jodoin, L. Ajdelsztajn, E. Sansoucy, A. Zúñiga, P. Richer, and E.J. Lavernia, Effect of Particle Size, Morphology, and Hardness on Cold Gas Dynamic Sprayed Aluminum Alloy Coatings, Surf. Coatings Technol., 2006, 201(6), p 3422-3429
R. Fernandez and B. Jodoin, Cold Spray Aluminum–Alumina Cermet Coatings: Effect of Alumina Content, J. Therm. Spray Technol., 2018, 27(4), p 603-623
D. Goldbaum, J. Ajaja, R.R. Chromik, W. Wong, S. Yue, E. Irissou, and J.-G. Legoux, Mechanical Behavior of Ti Cold Spray Coatings Determined by a Multi-scale Indentation Method, Mater. Sci. Eng. A, 2011, 530, p 253-265
W.-Y. Li, C.-J. Li, and H. Liao, Significant Influence of Particle Surface Oxidation on Deposition Efficiency, Interface Microstructure and Adhesive Strength of Cold-Sprayed Copper Coatings, Appl. Surf. Sci., 2010, 256, p 4953-4958
R. Huang, M. Sone, W. Ma, and H. Fukanuma, The Effects of Heat Treatment on the Mechanical Properties of Cold-Sprayed Coatings, Surf. Coat. Technol., 2015, 261, p 278-288
Z. Arabgol, M. Villa Vidaller, H. Assadi, F. Gärtner, and T. Klassen, Influence of Thermal Properties and Temperature of Substrate on the Quality of Cold-Sprayed Deposits, Acta Mater., 2017, 127, p 287-301
M. Meyer, S. Yin, and R. Lupoi, Particle In-Flight Velocity and Dispersion Measurements at Increasing Particle Feed Rates in Cold Spray, J. Therm. Spray Technol., 2017, 26(1–2), p 60-70
T. Schmidt, F. Gärtner, H. Assadi, and H. Kreye, Development of a Generalized Parameter Window for Cold Spray Deposition, Acta Mater., 2006, 54(3), p 729-742
P. Dupuis, Y. Cormier, M. Fenech, A. Corbeil, and B. Jodoin, Flow Structure Identification and Analysis in Fin Arrays Produced by Cold Spray Additive Manufacturing, Int. J. Heat Mass Transf., 2016, 93, p 301-313
Acknowledgments
The authors would like to acknowledge the financial support of NSERC.
Author information
Authors and Affiliations
Corresponding author
Additional information
This article is an invited paper selected from presentations at the 2018 International Thermal Spray Conference, held May 7–10, 2018, in Orlando, Florida, USA, and has been expanded from the original presentation.
Rights and permissions
About this article
Cite this article
Perry, J., Richer, P., Jodoin, B. et al. Pin Fin Array Heat Sinks by Cold Spray Additive Manufacturing: Economics of Powder Recycling. J Therm Spray Tech 28, 144–160 (2019). https://doi.org/10.1007/s11666-018-0758-3
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11666-018-0758-3