High-efficiency heat sink design via SLM-processed diamond TPMS CuCrZr alloy: Optimizing thermal-fluid performance through volume fraction control

Abstract

The thermal management of next-generation electronic and aerospace devices demands advanced heat dissipation solutions. While fin-type heat sinks enhance thermal conduction through extended surface areas, their performance is becoming inadequate for modern applications. Triply Periodic Minimal Surface (TPMS) structures, particularly the Diamond topology, offer superior heat transfer capabilities due to their high specific surface area and permeability. However, existing studies predominantly focus on aluminum alloys or titanium alloys, with limited research on copper-based TPMS structures. Here, we investigate Selective Laser Melting (SLM)-fabricated CuCrZr Diamond structures, a promising material for aerospace thermal management due to its exceptional thermal/mechanical properties. Through numerical simulations and experimental validation, we analyze the effects of pore size and convective area on thermal performance, benchmarking against conventional fin structures. Results demonstrate that increasing relative density enhances convective heat transfer but elevates pressure drop. At 0.4 m/s inflow velocity, the 50 %-porosity Diamond-Sheet variant achieves a peak average convection coefficient of 112,714.4 W/(m²·K) – 176 % and 209 % higher than Fin and Diamond-Solid structures, respectively, with a performance evaluation criterion (PEC) of 1.55.