Copper and aluminum heat sinks are well known for cooling electronics. The material you choose for a heatsink affects its cost, durability and performance. In this blog post we will compare copper and aluminum heat sinks, their properties, differences, pros & cons and best applications.
What are Heat Sinks?
Heat sinks in electronic devices absorb & dissipate heat from high temperature components such as CPUs, LEDs and power transistors. By removing heat they limit overheating and prolong the life of electronic parts. They are made of metals like copper or aluminum and have pins or fins to increase surface area for better heat dissipation.
Heat sinks are of two forms. One is active heat sinks which use blowers or fans for forced cooling and the other one is passive heat sinks which rely on natural convection.
Also See: What is a Heat Sink? Design, Manufacturing & Applications
What are Copper Heat Sinks?
Copper heat sinks are made of high purity copper (usually CDA110 alloy) and are designed for high usability applications. They have extraordinary thermal conductivity— mostly around 390 to 400 W/m·K which is 50% higher as compared to aluminum. Copper heat sinks can dissipate heat proficiently, withstand harsh conditions and are very durable. These properties make them best in cases where maximum cooling is needed.
What are Aluminum Heat Sinks?
Aluminum heat sinks are durable and lightweight parts to remove heat from electronic devices. Manufacturers use aluminum alloys such as 6061 or 6063 which have thermal conductivity ranging from 136 to 205 W/m·K. Because of their multifunctionality in design and extraordinary corrosion resistance aluminum heat sinks are used in many electronic cooling applications.
Main Differences between Copper Heat Sinks and Aluminum Heat Sinks
1. Thermal Conductivity
Copper Heat Sinks: Copper has higher thermal conductivity of around 400 W/ (m·K) (almost double of aluminum). Because of this better heat transfer property they distribute heat equally throughout its entire surface.
Aluminum Heat Sinks: Aluminum has average thermal conductivity of around 136 to 205 W/(m·K) which is 60% of copper’s conductivity. They compensate for this lower conductivity by having optimized designs and larger surface areas to keep good heat dissipation.
2. Corrosion Resistance
Copper Heat Sinks: Copper heat sinks are very durable and corrosion resistant especially in humid or harsh conditions. Because of copper’s chemical stability, these heat sinks will not only work steadily but last longer too.
Aluminum Heat Sinks: Aluminum naturally forms a protective oxide layer when it is exposed to air and it is good enough for most environmental conditions. But aluminum’s corrosion resistance may not be enough in highly alkaline or acidic environments.
3. Density and Weight
Copper Heat Sinks: Copper has a higher density of 8.9 g/cm³ so they are much heavier. Although more weight can be good for stability but it mostly limits copper heat sinks from being used in weight sensitive or mobile applications.
Aluminum Heat Sinks: Aluminum has a low density of 2.7 g/cm³, about one third of copper’s density and thus it is lighter in weight. So aluminium is a good option when weight reduction is necessary.
4. Manufacturing and Machinability
Aluminum Heat Sinks: You’ll find aluminum much easier to machine particularly when working through CNC and extrusion. Aluminum is soft so manufacturers can make thin profiles and complicated fins without wearing out tools. It is good for intricate cooling designs and high volume production.
See Also: Guide to Aluminum CNC Machining
Copper Heat Sinks: Machining copper is harder because of its hardness and tendency to work‐harden. Copper can’t be extruded. It needs special tools, precision machining and more energy during manufacturing. In such scenarios, experienced manufacturers like RICHCONN are needed. They use special tooling and the best CNC strategies to manufacture copper heat sinks for demanding applications.
See Also: CNC Machining of Copper
5. Aesthetics and Surface Treatment
Aluminum Heat Sinks: You can anodize aluminum heat sinks in many colors which improves its looks & corrosion resistance. For example RICHCONN gives anodizing services where you can match heat sinks to your brand colors. It is specially useful in consumer electronics where durability and appearance matters.
Copper Heat Sinks: Copper has a natural reddish brown color but its customization is limited. Although surface treatments can reduce oxidation of copper, it is usually not preferred when visual customization is a priority.
6. Electrical Conductivity
Copper Heat Sinks: Copper is very conductive as compared to aluminum. If your application needs both electrical and heat conduction like in RF equipment or power electronics then copper is usually a better choice.
Aluminum Heat Sinks: Aluminum also conducts electricity well but not as good as copper. In most heat sink applications this difference is not significant. But if your design needs electrical shielding or grounding then you may need to think about it.
7. Specific Heat Capacity
Copper Heat Sinks: Copper shows a lower specific heat capacity of around 385 J/kg·K so it heats up faster as compared to aluminum. But because of its higher thermal conductivity it can quickly transfer heat away from the source. This makes copper better for applications with high and constant heat generation.
Aluminum Heat Sinks: Aluminum gives specific heat capacity of around 900 J/kg·K. This higher heat capacity means aluminum can absorb more heat energy before increasing its temperature. So aluminum heat sinks work well in applications with ordinary or fluctuating heat loads.
8. Affordability and Cost
Copper Heat Sinks: Copper heat sinks are much more expensive so the final product price will also be higher. Because of these high costs copper is usually chosen only when price is not a concern and highest heat removal is needed.
Aluminum Heat Sinks: Aluminum is much cheaper and its price per metric ton is around one‐third of copper. Working with a manufacturer like RICHCONN can help you save more. They give insights about design‐for‐manufacturability (DFM) and bulk pricing which additionally reduces cost.
9. Recycling and Environmental Impact
Copper Heat Sinks: Although copper is recyclable but its recycling process uses more energy as opposed to aluminum recycling. It has a lower recycling rate. Also its mining has a larger environmental footprint so copper heat sinks are collectively less sustainable.
Aluminum Heat Sinks: You can recycle aluminum faster and it saves up to 95% of energy as compared to primary production. Aluminum keeps its properties even after multiple recycling cycles. Also it is lighter and abundantly available which not only reduces transportation but environmental impact too.
10. Applications
Copper Heat Sinks: Copper heat sinks are used in telecom infrastructure, electric vehicles, power electronics and high performance computing. These applications need reliability and high heat dissipation so copper is the go‐to choice.
Aluminum Heat Sinks: You’ll find aluminum heat sinks in LED lighting, automotive systems, consumer electronics as well as in industrial equipment. They’re popular in these fields because they’re affordable, lighter and can be used multiple times.
Pros and Cons for Copper Heat Sinks and Aluminum Heat Sinks
Copper Heat Sinks
Pros
- Copper heat sinks have extraordinary thermal conductivity of about 400 W/m·K. They can transfer & dissipate heat very fast.
- They’re corrosion resistant and durable. So they can work well over extended periods even in humid or harsh conditions.
- Copper has high specific heat capacity. So copper heat sinks can not only absorb and hold large amounts of heat but give stable cooling during heavy workloads too.
Cons
- Copper heat sinks are more expensive as compared to aluminum, even as much as 3 times. So it is not practical for projects with tight budgets.
- Copper is harder to machine & form. But you can solve this problem by working with manufacturers who have experience in copper machining like RICHCONN.
Aluminum Heat Sinks
Pros
- Aluminum heat sinks are lighter because of aluminium’s density of 2.7 g/cm³. Lighter is better for weight sensitive applications and portable devices.
- Aluminum can be easily extruded and machined. You can get complicated and custom heat sink designs according to your needs.
- Aluminum heat sinks are budget friendly because aluminum is cheaper as compared to copper. So it is perfect for budget constrained works.
Cons
- Aluminum heat sinks have lower thermal conductivity in comparison with copper. So they’re less preferred for high power or high functionality applications.
- To get good cooling behavior in high power or compact equipment you may need additional cooling treatments or larger aluminum heat sinks.
Which One Is Better? – Copper or Aluminum Heat Sinks
It depends on your application requirements. Copper heat sinks have nearly twice the thermal conductivity of aluminum – 400 W/m·K vs 205 W/m·K. So copper heat sinks are better for compact or high functionality systems where heat dissipation is the main goal. On the other hand aluminum heat sinks are cheaper, lighter and chosen for applications where weight and cost is the key factor like in consumer electronics.
Also See: Top 10 Heat Sinks Manufacturers And Suppliers In China
To Sum Up
Aluminum heat sinks have an advantage of cost, weight and multifunctionality. Copper heat sinks on the other hand are better thermal conductivity and are good for more demanding situations. So in the end it’s your projects needs which decides the best option for you.
If you need any kind of custom heat sinks designed exactly to your needs then Richconn is your best option. You can contact us anytime.
Related Questions
How does the heat sink material affect total system design?
Chosen material affects thermal output, weight and cost of a heat sink. These aspects decide the complexity, size and cooling productivity of your system design.
Does manufacturing of copper and aluminum heat sinks consume different amounts of energy?
Yes producing aluminum heat sinks consumes less energy because of easy extrusion & machining. In contrast copper uses more energy because it has some complications in machining and has high density as well.
Which material encourages more complex heat sink designs?
Aluminum is easier to extrude & machine so its heat sinks permit intricate and more complex geometries.
Do copper and aluminum heat sinks have different carbon footprint?
Yes aluminum heat sinks come with a lower carbon‐footprint. This is because aluminum is recyclable and consumes less energy during processing as compared to copper.
Are there hybrid heat sinks which combine both copper and aluminum materials?
Yes hybrid heat sinks exist. They combine copper’s thermal conductivity with aluminum’s lightweight which is a balanced solution for cost and best results.
