Aluminum Heat Sink vs Copper Heat Sink：Which is best？
Aluminum heat sinks and copper heat sinks are two of the most common heatsinks we see, so which one is the best? These following discussions can help you pick them better:
What are copper and aluminum heat sinks?
A heat sink is a type of radiator piece used to absorb and transfer heat generated by various electrical devices and equipment and distribute it to the surrounding environment. It is usually made of highly thermally conductive aluminum or copper material with a large surface area and an optimized structure to improve heat dissipation efficiency.
Copper and aluminum heatsinks work and are similar in construction, but they differ in price and thermal performance. Because copper metal has better thermal performance, it wins in CPU or cell phone heatsinks.
But aluminum heatsink through the design of reasonable extruded aluminum heatsink structure (such as increasing the surface area of the heatsink, using fin structure, etc.). It has attracted more manufacturing industries to use it to help dissipate heat from their equipment.
Want to know what their exact differences are? Look no further than these pros and cons below.
Aluminum Heat Sinks advantages:
1. good thermal performance:
Aluminum is an excellent thermal conductivity material. Thermal conductivity is three times higher than steel, although slightly lower than copper, but aluminum heatsinks can dissipate heat faster, effectively reduce the temperature of the equipment, to protect the normal operation of the equipment.
2. Light weight:
The density of aluminum is lower than copper, so aluminum heat sinks are relatively lighter. The weight of the whole equipment can be reduced after installing the aluminum heat sink. So this advantage makes it used in cell phone cooling and computer cooling.
3. Machinability:
Aluminum heatsink is manufactured by aluminum extrusion process. But it can be machined into various shapes and sizes according to changing the size of the mold. It can be drilled or slotted by CNC subsequent processing. So it can meet the cooling needs of different devices.
aluminum heat sink disadvantages:
1. Lower hardness:
The hardness of aluminum is lower than that of copper, so aluminum heat sinks are more susceptible to deformation or damage from external forces. When faced with impact or external forces. Aluminum will be more fragile than copper.
2. Limited corrosion resistance:
Although aluminum has some corrosion resistance. However, its corrosion resistance may not be as good as that of copper in strong acidic and alkaline corrosive environments. Therefore, copper will be more reliable than aluminum when facing extreme environments.
Advantages of copper heat sinks:
1. Excellent heat dissipation:
Due to the excellent thermal conductivity of copper. Compared with aluminum, copper heatsinks can quickly dissipate heat to ensure stable operation of the equipment. This advantage can meet the heat dissipation of large server equipment. Or the heat sink case of battery charger.
2. Better corrosion resistance:
Copper heat sinks will be more corrosion resistant than aluminum. Copper metal is chemically stable and is not easily affected by other metals. Therefore, choosing it as a heatsink material can improve the service life of the heatsink.
Disadvantages of aluminum heatsink:
1. greater weight:
Copper has a higher density. Compared to aluminum, it can be relatively heavy. This may increase the overall weight of the equipment. If a large copper heatsink is used it will increase the weight of the equipment affecting safety and installation.
2. Higher cost:
The raw material of copper is expensive. At April 2024 prices, copper is four times more expensive than aluminum. This results in a relatively high manufacturing cost for copper heat sinks. It is difficult for projects with lower budgets to want to use copper heat sinks.
So what would be the difference between copper heat sinks?
The table below directly show the difference between an aluminum heatsink and a copper heatsink:
| feature | Aluminum Heat Sink | Copper Heat Sink |
|---|---|---|
| Heat Conductivity | thermal conductivity of about 238W/(m·K)（0℃～100℃） | The thermal conductivity is about 397W/(m·K) |
| Density & Weight | 2.7g/cm³ | 8.9g/cm³ |
| cost | Lower, production cost 1/4 of copper | Most expensive |
| corrosion resistance | Better, but may be sensitive to some strong acid | Excellent, relatively resistant to corrosion |
| processability | Good formability and ease of manufacture | Difficulty in processing |
| application | wide range，for example: PCB heatsink, LED heat sink and Inverter Heat Sink | CPU Heat Sink |
| Appearance & Aesthetics | Bright appearance with powder coating or anodized finish | mill finish, may not suit all design styles |
| Safety | Aluminum heat sinks are non-toxic and do not release toxic gases when burned | Burning copper releases toxic gases, but it has a high burning point. |
| Maximum working temperature | 660.4℃ | 1083.4±0.2℃ |
| environmentally friendly | Aluminum alloy or aluminum can all be recycled | High recycling costs |
Choosing the best heatsink for your project
Aluminum and copper heatsinks have their own advantages and disadvantages. When choosing a heatsink, you need to consider the specific application scenario, equipment requirements, cost budget and other factors.
- When your project budget is low: aluminum heat sinks are the best. This is because it is 1/4 the price of copper, even though copper heatsinks perform better. But it is quite expensive.
- Large heatsinks are required: Aluminum heatsinks are a better option because aluminum is 1/3 the weight of copper. The light weight of large aluminum heatsinks reduces shipping costs and makes installation less difficult.
- Complex heatsinks are needed: extruded aluminum heatsinks are the best because aluminum extrusion can be designed in different shapes and sizes. When confronted with more complex cross-section design requirements copper heatsinks cannot be accomplished.
- Needs to last: Copper heatsinks are better because the maximum operating temperature of a copper heatsink is twice that of aluminum. It is able to dissipate heat and lower the operating temperature of the equipment for a long time at high temperatures.
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