Manufacturing of copper cold plates via metal fused filament fabrication and their characterization

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MehmetCanberkBacikoglu_MastersThesis.pdf

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2023-1

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Bacıkoğlu, Mehmet Canberk

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Unlike traditional manufacturing methods, Additive Manufacturing (AM) is one of the most popular methods to produce parts with complex geometries using a wide range of materials. Atomic Diffusion Additive Manufacturing (ADAM) is an AM method to manufacture metal parts by using filaments which include metal powders encased in plastic binders. Various types of materials can be 3D printed with this method, including stainless steel, copper, tool steel, Inconel, and titanium. In this study, ADAM method is used to manufacture cold plates with interior channels used to cool down circuit boards for electronic applications. Before the fabrication of cold plates, test parts that replicate some parts of the cold plates are manufactured to characterize material properties and control the quality of initial parts. CMM measurements, surface roughness measurements, Micro-CT and X-ray scans, density determination with Archimedes method, SEM analysis, and thermal conductivity measurements are conducted on the test parts. Then, interior channels are generated with different cross sections considering supportless manufacturing where the liquid stream passes. Pressure drop and temperature mapping of the cold plates manufactured with copper are observed with experiments. According to the results, the lowest pressure drop is obtained for the cold plate with triangle cross-section. Cold plate with droplet cross-section has the minimum temperature value on the resistor and has the highest performance rating among the other cold plates manufactured via ADAM method. This design approach shows that ADAM can be used for its speed and wide range of materials, and can be adapted for various fast-prototyping industries that require complex interior channels in mechanical parts.

Subject Keywords

Atomic diffusion additive manufacturing, Cold plate, Interior liquid channel, Channel cross-section, Material characterization, Quality control

URI

https://hdl.handle.net/11511/102091

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Graduate School of Natural and Applied Sciences, Thesis

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Citation Formats

M. C. Bacıkoğlu, “Manufacturing of copper cold plates via metal fused filament fabrication and their characterization,” M.S. - Master of Science, Middle East Technical University, 2023.