1994-03-01

High Performance Heat Sink Fabrication Issues 940853

Advances in high performance electronics have resulted in the need to develop fabrication processes for a variety of exotic new materials. In order to tailor desired thermal performance characteristics, the materials designer has relied on metal matrix systems with refractory metal or ceramic basis. The ease of fabrication formerly experienced with lower performance Nickel-Iron systems could no longer be realized.A novel material system will be discussed where the performance of Nickel-Iron based alloys is augmented through the selective addition of high performance Silver. This system competes favorably with the refractory metal and ceramic based systems while offering significant fabrication advantages.The Nickel-Iron system readily adapts to a list of standard metallurgical fabrication processes. Two processes in particular i.e. machining and plating will be addressed. Standard machining operations were performed on a variety of metal matrix systems. Relative material removal rates, tool wear, surface finish, and machining costs are reported herein. These same materials were subjected to standard plating tests and overall processing costs developed. The conclusion addresses the relative fabrication costs for each of the material systems investigated.

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