Selective laser melting of heat transfer devices

Purpose - To fabricate and characterise novel heat sinks manufactured by selective laser melting (SLM). The investigation explores features of SLM produced heat sinks that may be exploited to improve their heat transfer capability. Design/methodology/approach - The study was conducted on heat sinks manufactured from 316L stainless steel and aluminium 6061. The heat transfer devices' thermal and pressure drop performances were determined by experimental test. Findings - The research demonstrates the performance enhancements that can be realised by using novel heat sink designs, fabricated by SLM, over conventional pin fin arrays. aluminium 6061 is used with the process to illustrate the improvement in heat transfer provided by higher conductivity feedstock materials. Research limitations/implications - Although the manufacturing technique is still in the development stage and the heat transfer devices that have so far been manufactured should not be considered optimal, the potential for creative new designs and applications is clear. This study highlights the need to develop the SLM process parameters to allow the repeatable production of heat transfer devices from higher conductivity metals with controllable surface finishes. Originality/value - This paper outlines the design issues and performance of novel heat transfer devices fabricated using SLM. A new material, aluminium 6061, is introduced to the family of materials that can be processed with SLM and example heat sinks are tested.