A lightweight additively manufactured two-phase integrated natural convection heat sink
Bibliographic record
Abstract
• Entirely hollow two-phase integrated heat sink fabricated by laser powder bed fusion. • Experimentally tested in thermosyphon and wicked modes using a LPBF grooved wick. • 19.2 % reduction in thermal resistance compared to baseline solid conduction heat sink. • 34 % weight reduction owing to entirely hollow architecture. Natural convection heat sinks are important for applications requiring passive or silent cooling. Conventional solid-finned heat sinks have limited performance due to the heat-spreading resistance of the base and fins, especially for small, localized heat sources. Two-phase heat sinks with embedded heat pipes can significantly improve thermal spreading, and metal additive manufacturing (AM), especially laser powder bed fusion (LPBF), can allow for innovative designs of these heat sinks in terms of thermal performance and weight savings. This study investigates the thermal performance of a fully hollow heat sink architecture fabricated by LPBF. Heat spreading is accomplished by the fully integrated internal two-phase region and results in lower heat sink thermal resistance and mass. Two dimensionally identical heat sinks were fabricated with one solid-finned heat sink as a benchmark. The second heat sink was created with a hollow base and hollow fins and tested in two different operating modes: thermosyphon mode and heat pipe mode with a unique AM-hatched grooved wick. The tested AM-hatched grooved wick had a groove width of 0.19 mm, a groove height of 0.8 mm, and a hatch spacing of 0.43 mm. The heat sinks were fabricated using AlSi10Mg metal powder. The two-phase heat sinks were tested in air-cooled natural convection conditions. All thermal tests were performed for the heat sink in a vertical orientation. Acetone was used as the working fluid with filling amounts of 9, and 12 cm 3 . Results show a maximum reduction in thermal resistance of 19.2 % for the heat sink with the LPBF hatched grooved wick with 12 cm 3 acetone compared with the baseline solid heat sink while weighing 34 % less.
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How this classification was reachedexpand
Full frame distilled prediction
Teacher imitationNot calibrated prevalence, not ground truth. Human validation pending. Learned from the 10,348 direct Codex labels and 10,348 direct Gemma labels. Candidate is the union of thresholded teacher heads; consensus is their intersection. These outputs are machine_predicted_unvalidated and are not human labels or direct frontier model labels.
Codex and Gemma teacher scores by category
| Category | Codex | Gemma |
|---|---|---|
| Metaresearch | 0.000 | 0.000 |
| Meta-epidemiology (narrow) | 0.000 | 0.000 |
| Meta-epidemiology (broad) | 0.000 | 0.000 |
| Bibliometrics | 0.000 | 0.000 |
| Science and technology studies | 0.000 | 0.000 |
| Scholarly communication | 0.000 | 0.000 |
| Open science | 0.000 | 0.000 |
| Research integrity | 0.000 | 0.000 |
| Insufficient payload (model declined to judge) | 0.000 | 0.000 |
Machine scores (provisional)
The two teacher heads of the student model, read on this work. A score orders the frame for review; it never asserts a category, and the validation status ships verbatim with every row.
Baseline scores from an immature model (maturity gate not passed, 7 training rounds). Scores rank; they never assert a category.
score_only:v0-immature-baseline · verbatim from the scoring run: score_only means the number may rank works, and no category label ships from itClassification
machine, unvalidatedMachine predicted; a candidate call from one teacher head, not a consensus.
How this classification was reached, model by model and score by score, is at the end of the page under "How this classification was reached".