Wellste: Your Leading Die Casting Heat Sink Manufacturer

This ensures that the process is always used for the right application, especially in the LED industry.

Wellste die casting heat sinks are manufactured in near net shape and range in complexity. We give high solutions for cooling problems and the best in quality die cast heat sinks. Wellste is ISO 9001 certified company that has been manufacturing die cast heat sinks with superior materials for competitive prices. Our die casting heat sinks are designed with expertise and can meet your specific needs.

Wellste die casting heat sinks are processed with the most advanced technology and are tested in safety percussions. We have the widest range of flexibility in manufacturing die cast heat sinks to enhance our products in all aspects.

Wellste casting heat sink will be operated by advanced vibratory tumbling machine to remove all surface sharply deburrs and make a fantastic elegant appearance.

Wellste is the leading die casting heat sink manufacturer and supplier. We are one of the best longtime business partners in die cast heat sink industry.

We provide a huge quantity of die casting heat sinks. We also provide design assistance to our customers, so you can freely send us your custom design heat sink. All our die cast heat sink products are of high quality and competitive price.

Wellste die casting heat sink designed and widely used for higher volume cooling applications that require higher thermal conductivity feature.

Through die casting, you can eliminate or reduce the final machining operation for the heat sink. With Wellste die-cast heat sink you can significantly save cost.

Wellste die casting heat sink provides excellent thermal performance. Heat can be spread directly and fastly without additional resistance.

This high-pressure casting heat sink is an efficient option for specific applications which demand lightweight and superior cosmetic surface quality. We can provide all heat sinks that will fit any designs and specifications.

In Wellste, we can produce unique shapes and sizes of the heat sinks by die casting. And through weight requirements and high volume production needs, we can satisfy each client’s business demand.

Our die casting heat sink range is widely praised by our clients and customers for its high mechanical strength, robust construction, and durable performance.

We manufacture die cast heat sinks using aluminum alloy number is A380, A356, ADC12 and so on,  These material are lighter and has higher thermal conductivity than other material.

Aluminum die casts heat sink can resist extreme control conditions.

Die Casting Heat Sink: The Ultimate FAQ Guide

This guide answers all your questions on die cast heat sinks.

Whether you want to learn about the manufacturing process, features, working principle or any performance criteria, you will find all information right here.

Keep reading to learn more.

What Is A Die Casting Heat Sink?

This is a device that you will use to cool down the temperature levels of various components.

A die casting heat sink applies heat dissipation effect which happens when a hot substance is within a cooler surrounding.

The die casting heat sink will transfer heat from the hot component to the cooler environment thereby cooling the component.

A Die Cast Heat Sink

How Does Die Casting Heat Sink And Extruded Heat Sink Compare?

A die casting heat sink is made using aluminum alloys to make a porosity-free product.

Die casting allows you to make complicated shapes with minimal machining.

Besides, the thermal conductivity of die casting heat sink is less than that of extruded heat sinks.

An extruded heat sink is also made from mainly aluminum and is suitable for large and small quantities.

Besides, you can form linear-shaped extruded heat sinks and is suitable where you need linear airflow.

An Aluminum Extruded Heat Sink

What Is The Operational Principle Of A Die Casting Heat Sink?

There are numerous variations of heat energies that different devices will emit.

These include frictional, mechanical, or electrical energies.

A die casting heat sink will inhibit the accumulation of heat within the unit thus enhancing its durability.

Here are the operational principles of a die casting heat sink:

• Heat generation at source

The source is any system that will generate heat and needs a mechanism to remove the heat to operate effectively.

Such sources include:

1. Mechanical sources
2. Electrical sources
3. Frictional sources
4. Chemical sources
5. Nuclear sources
6. Solar sources

• Heat transfer from source

Here, heat will move from the source to the die casting heat sink.

For instance, in a direct heat sink-contact use, heat moves from the source to die casting heat sinks through natural conduction.

Besides, the thermal conductivity of the die casting heat sink material will affect the heat transfer rate.

For this reason, most die casting heat sinks use aluminum or copper as they have high thermal conductivity.

• Heat distribution in die casting heat sinks

In this stage, heat will move to the die casting heat sinks either actively or passively.

This happens as the heat moves across the variation within the thermal gradient to a low-temperature from a high-temperature environment.

For this reason, the thermal profile of the die casting heat sink may be inconsistent.

This means die casting heat sinks are hotter at the source and cooler at the extremities.

• Heat moves from heat sinks

This process will rely on the temperature gradient of the die casting heat sink and the operating fluid.

Besides, this is mostly air or a liquid that has no electrical conductivity.

The operating fluid pass across the surface of the warm die casting heat sink.

It then uses convection and thermal diffusion to eliminate heat from the hot surface to the surrounding environment.

This process also relies on the thermal gradient to eliminate heat from the die casting heat sink.

Therefore, if the temperature of the die casting heat sink and ambient temperature are equal, there will be no heat removal.

It is in this phase that the surface area of the die casting heat sink is vital in the heat dissipation process.

There will be more thermal convection and diffusion if the die casting heat sink has a large surface area.

Thermal Convection And Diffusion Helps Transfer Heat To The Surrounding Environment

Does A Die Casting Heat Sink Come With Fins?

A die casting heat sink operates by dissipating heat and fins are a vital part of this device.

Fins are narrow plates that allow heat to move from the hot area to cold areas of the environment.

Heat will enter one end of the fins and move as it dissipates to the environment till it reaches the other end.

The fins on the die casting heat sink lower heat transfer to other sides as they continue minimizing the temperature of these components.

Besides, the spacing between each fin will play an important role during heat dissipation.

Narrow spacing between each of the fins will lower the rate of heat transfer.

This means the components will take more time to cool down.

Alternatively, if the spacing is wide, air will easily pass through the fins thus enhancing the cooling effect of the components.

Fins Are narrow Plate Protrusions On A Heat Sink

What Are The Uses Of A Die Casting Heat Sink?

Several industries use die casting heat sinks in their devices.

Besides, they are cost-effective and accurate making them attractive to several buyers.

Die casting heat sinks find their application in almost all of today’s industries.

Some of the applications entail the following:

• Light-emitting diodes [LED]

LED industries use die casting heat sinks to ensure an efficient heat flow in their products.

Besides, you need to regularly regulate thermal variations within LED lights and screens.

The die casting heat sink assist in minimizing heat buildup thereby enhancing their durability.

Also, the die casting heat sinks will distribute heat uniformly within these devices and offer cooling capabilities.

• Automotive industry

The use of die casting heat sinks in the automotive industry is proving to be important.

For instance, you will attach die casting heat sinks on sensors and control systems within automotive.

Also, you can combine die casting heat sinks and radiators within engines to enhance their performance.

Besides, die casting heat sinks are finding their place in e-mobile sensors and engines.

Die Casting Heat Sinks Are Combined With Radiators To Enhance Performance

How Does Passive And Active Die Casting Heat Sink Compare?

Die casting heat sinks can come in two major configurations, these include active and passive.

Here is how these two compare:

• Passive die casting heat sink

Passive Die Casting Heat Sink

This type of die casting heat sink applies the convection method in cooling components.

Heat will move towards the fins of the die casting heat sink because of its buoyancy.

The heat will not move to the components through other control systems or force.

A passive die casting heat sinks will achieve a high capacity of heat dissipation and natural convection by using heat spreaders.

They may also utilize the heat sink to achieve maximum radiation and convection heat transfer methods.

Besides, the convection process happens continuously and generates an airflow within and around the die casting heat sink.

Passive die casting heat sinks are affordable but are not as effective as active die casting heat sinks.

To maintain an optimal operating temperature level, die casting heat sinks rely on heat spreaders, heat pipes, heat sinks, or thermal interface materials [TIM].

The benefits of a passive die casting heat sink include the following:

1. Energy efficiency
2. Low financial cost

• Active die casting heat sink

An Active Die Casting Heat Sink

This type of die casting heat sink used extra fans within it to achieve suitable cooling effects within the components.

The fans will blow hot air that is within the component towards the die casting heat sink.

Besides, fans find their use in computer cases hard drives, chipsets, etc.

This effect will increase the rate of fluid flow during the convection which increases heat removal rate.

In some instances, you will use a case fan and not a common fan to draw cool air from the environment.

It will also blow out the hot air from within the component.

This technique is efficient as it will enhance the overall thermal gradient.

To achieve an optimal heat transfer rate, they may use active cooling solutions such as:

1. Fans or blowers
2. Thermoelectric coolers [TECs]
3. Forced liquids

Besides, these two, there is also hybrid die casting heat sinks.

These heat sinks make use of both active and passive die casting heat sinks.

However, they are less common and mostly work with control units to cool the unit depending on the temperature needs.

When the unit is operating at a cool level, the source of forced air is inactive, and will only cool the unit passively.

As the source achieves a higher temperature level, the active cooling units engage and this enhances the cooling rate of the die casting heat sink.

What Is A High Density Die Casting Heat Sink?

High density die casting heat sinks are an efficient version of heat sinks than the standard versions.

This technique advances the heat dissipation process as it operates together with alloys that are thermally managed.

High density die casting heat sinks will use a combination of various metals and metal alloys.

This makes the overcome the drawbacks that you will find in traditional die casting heat sinks.

Besides, the components you obtain via high density die casting offer more thermal and mechanical properties.

Also, high density die casting heat sinks are expensive than normal die casting heat sinks as they use several metal alloys in their production.

They also require more machining in their production which increases their cost.

How Can You Increase The Heat Absorption Rate Of A Die Casting Heat Sink?

A die casting heat sink can decrease the temperature of mechanical and electrical systems since they can absorb heat.

Also, you can enhance the heat absorption rate of a die casting heat sink by applying different techniques.

Fins on the die casting heat sinks has a direct influence on its operation.

Besides, you can increase or decrease the number of fins and the spacing between the fins to enhance how it operates.

Also, you can include inserts within the die casting heat sink to increase the heat absorption rate of these devices.

This effect will form continuity within the die casting heat sink hence enhancing the heat absorption rate of die casting heat sinks.

Which Materials Are Suitable For Making A Die Casting Heat Sink?

The material that you use when making a die casting heat sink needs to be a good conductor since it operates by eliminating heat from the components.

The main materials for making a die casting heat sink are aluminum and copper.

Copper material has the highest level of thermal conductivity when you compare it to other suitable die casting heat sink materials.

Besides, copper has a conductivity of 223 BTU making it suitable for making heat exchanging components such as die casting heat sinks.

 A Copper Die Casting Heat Sink

Aluminum has low conductivity than copper material and has a thermal conductivity of, for instance, 118 BTU.

When you use aluminum with high purity levels, it will produce suitable die casting heat sinks.

These heat sinks are efficient are eliminating heat from components.

However, it is difficult to die cast aluminum therefore you will add impurities to enhance the die casting process.

These impurities will affect the thermal performance hence lowering its thermal conductivity.

A majority of aluminum die casting heat sinks use A380 as it will enhance the structural integrity of the component.

Another aluminum alloy that you can use to make die casting heat sinks is and A356.0. as it improves the thermal property of the component.

This version has a thermal property that is similar to the thermal conductivity of aluminum material from machined or extruded heatsinks within 160-200 W/m-K.

Die casting heat sinks are suitable for large volume usages that can operate with initial Non-Recurring Engineering [NRE] charges.

Also, you will usually cover around 5000 pieces of the initial Non-Recurring Engineering [NRE] by the lowered component price.

After setup, the manufacturing time is less than other techniques and will save you money when you make large volumes of die casting heat sinks.

Another advantage is that die casting heat sinks can contain complex configurations that are difficult to make using other techniques.

When you produce die casting heat sinks with a shape similar to the final product, you will lower the finishing machining process.

Does The Size Of A Die Casting Heat Sink Affect Its Thermal Management?

Three factors will affect the cooling rate of a die casting heat sink.

These factors include the following:

• Surface area
• Material construction
• Airflow around the die casting heat sink

The size of the surface area of the die casting heat sink will affect its thermal management.

A die casting heat sink with a large surface area will increase the rate of heat flow.

The bigger versions of die casting heat sinks contain several fins or more space between the fins.

Both of these will make the die casting heat sink better at conducting heat from the source and releasing it to the environment.

Besides, a large surface area enables more air to flow through the fins allowing heat to move outside via convection thereby enhancing the cooling effect.

How Will You Increase The Design Efficiency Of A Die Casting Heat Sink?

A die casting heat sink will offer an efficient and effective solution to conducting heat.

Here are some ways you can use to increase the efficiency of the die casting heat sink:

• Fins

The placement of fins within a die casting heat sink allows heat to flow from the source to the cool surrounding environment.

When you increase the aspect ratio of the fins, the efficiency of the die casting heat sink will also increase.

Besides, you can increase the rate of heat flow by reducing the distance between the bottom of the die casting heat sink and the fins.

The shape and size of the fins will also affect the efficiency of the die casting heat sink.

For instance, the geometry and thickness of the fins will increase their efficiency by using radial or elliptical fins.

Besides, the configuration of the fins relies on the component that is working with the die casting heat sink.

Heat flow within the die casting heat sink also relies on the arrangement of the fins.

• Die casting heat sink attachment

The technique you use when attaching a die casting heat sink to the component device will affect heat conductivity.

Always place the die casting heat sink in a suitable place to increase its efficiency.

For instance, you can use placement methods such as:

1. Flat spring clips
2. Standoff spacers
3. Thermal conductive tapes
4. Epoxy
5. Z-clip wire forms
6. Push pins
7. Threaded standoffs

• Material construction

The efficiency of the die casting heat sink also relies on material construction.

Always use a material with the highest thermal conductivity when making a die casting heat sink to increase its efficiency.

Besides, the material construction you will use to make the die casting heat sink relies on factors such as cost and thermal conductivity.

How Does Hot Chamber And Cold Chamber Die Casting Heat Sink Compare?

In hot chamber die casting, you will melt the die casting alloy within a furnace within the machine.

However, in cold chamber die casting, you will melt the die casting alloy in different furnaces outside the equipment.

The casting cycles in hot chamber die casting are shorter hence require a high production rate.

Cold chamber die casting has long casting cycles thus has a lower production capacity.

Hot chamber die casting is suitable for alloys with a low melting point while cold chamber die casting is suitable for alloys with high melting points.

Cold chamber die casting has a shorter tool life compared to hot chamber die casting.

Besides, you need more safety requirements in a cold chamber than hot chamber die casting.

Cold chamber die casting is suitable for metal alloys such as magnesium, copper, aluminum, brass, etc.

Hot chamber die casting is suitable for metal alloys such as lead, zinc, etc.

What Are The Alternatives To Manufacturing Heat Sinks Besides Die Casting?

Some of these alternatives include the following:

• Extrusion

In this method, you will force hot metal billets via steel die when making aluminum heat sinks.

Extrusion is a fast, economic, and effective technique of manufacturing heat sinks from ductile materials such as aluminum 1050.

Besides, you will anodize extruded aluminum heat sinks before application.

• Skiving or scarfing

In this method, you will cut the material substance into slices.

This method is suitable for making flared or plate fin heat sinks.

Skiving allows you to make thin and dense fins than in the extrusion process.

It will also offer surface roughness that will slightly increase the surface area of the heat sink.

• Milling

This is the process of cutting off material from a blank piece.

Milling is cost-effective and can make heat sinks with any shape from heat sink metal alloys such as aluminum.

Besides, it may be expensive to make milled or machined heat sinks than the other alternative methods when manufacturing in bulk.

However, you can make these heat sinks quickly.

• 3D printing

Recent technological advancements in additive copper production make 3D printing of heat sinks a viable option to traditional versions.

The most successful technologies for this purpose are:

1. Directed energy deposition
2. Powder bed fusion

What Are The Benefits Of Using An Aluminum Die Casting Heat Sink?

Aluminum, being a good conductor, offers the following benefits:

• Design

Aluminum material is easily moldable enabling you to make designs that increase the feature of the die casting heat sink.

The design requires minimal to no machining making them cost-effective.

• Electrical conduction

Aluminum conducts electricity meaning you can use it in electrical devices.

They can also provide EMI shields with the appliances.

• Pin fin design

Aluminum has pin fin designs that offer more density within a small area and will perfect the orientation of the die casting heat sink.

Aluminum Die Casting Heat Sink Is A Good Conductor

What Are The Processes Of Die Casting Heat Sink?

Some of the processes in die casting entail:

• Creating die molds
• Lubricating the die
• Filling die with molten metal
• Ejecting from die half cover
• Shakeout from die half ejector
• Trimming and grinding surplus material
• Surface finishing

What Are High Pressure Die Casting Heat Sinks?

A high pressure die casting heat sink is cost-effective alternatives for large volume usage.

Also, they are suitable for weight-sensitive applications that need superior surface finish or complex designs not possible with other methodologies.

Are There Disadvantages Of Using Die Cast Heat Sink?

Some of the disadvantages include:

• Occupying large area
• Costly to manufacture
• Loudness during operation
• Inaccessibility to certain parts

Die Casting Heat Sink Occupy a Large Area And Are Costly To Manufacture

How Do You Check Quality Of Die Casting Heat Sink?

There are various methods you can use to determine the performance of die casting heat sinks.

These include the following:

• Heat transfer theoretical method

In this method, you will use fluid dynamics and heat transfer to determine the quality of a die casting heat sink.

• Numerical method

This method offers qualitative or even quantitative fluid flow prediction to determine the quality of die casting heat sink.

• Experimental method

This is a popular method of checking the quality of die casting heat sinks

Additional Resources:

• Extruded Heat Sink
• Forged Heat Sink
• Custom Heat Sink
• Anodized Aluminum Heat Sink
• Die Casting Process

For all your die cast heat sinks, contact us now.