Heat Dissipation of Open-Cell-Type Aluminum Foams Manufactured by Replication-Casting Process

Abstract

Open-cell-type aluminum foam demonstrates excellent heat dissipation owing to interconnected pores. In this study, open-cell-type aluminum foams with various pore sizes and porosities were fabricated using the replication-casting process, which is a relatively simple process. The porosity of the manufactured foams ranged from approximately 55% to 62%. To assess the heat dissipation of the manufactured foams, an air-cooling system was designed. The device could pass a controlled amount of air through the connected pores, simultaneously measuring pressure drop ∆P and temperature changes. It was confirmed that the open-cell-type aluminum foams exhibited a very high cooling rate in the initial cooling phase, and the thermal behavior is influenced by structural characteristics. At a porosity of 62%, the initial maximum cooling rate was measured to be 1.41 ℃/s for a pore size of 0.7~1.0 mm, and it was observed to significantly increase to 3.82 ℃/s for a pore size of 2.8~3.4 mm. Furthermore, for the same pore size, an increase in porosity resulted in an increase in the initial cooling rate. Lager pore sizes and higher porosities led to lower pressure drop ∆P and improved airflow, enhancing the cooling efficiency of open-cell-type aluminum foams.