Thermal Management of Power Components and Electric Systems using Channels Embedded in Metallic Parts by Friction Stir Channelling

Abstract:
TWI Ltd has recently invented a new sub-surface machining technique called CoreFlow(TM). This new solid-state process is a derivative from friction stir welding that allows for sub-surface networks of channels to be machined within monolithic metallic parts in a single step. CoreFlow(TM) has been recently developed as an alternative and efficient manufacturing process for thermal management systems. These include applications such as cold plates for dissipating heat produced by electronic components (e.g. IGBTs, LEDs, CPUs/GPUs) or electric systems (e.g. motors, batteries, power supplies). Flat and tubular demonstrators were successfully manufactured in several grades of aluminium, pure copper and multi-material claddings.