Design Study of Hole Types for Improved Cooling of Experimental Heatsinks Manufactured by SLM Technology Using an AlSi10Mg Alloy

The purpose of this article is to inform the reader about the results of an experimental investigation into the appropriate manifold geometry for an air-cooled inverter, which is manufactured from an AlSi10Mg powder material using SLM technology. The best approach is to optimize the part geometry for SLM technology so that the placement of support structures required for model fabrication is eliminated as much as possible. A suitable solution was selected based on the design of the most appropriate cross-sectional shape of the openings with the smallest dimensional accuracy deviation and shape deformation. In the experiment, three test specimens were designed; each of them contained eight holes of different shapes, particularly square, rhombic, and circular, with a given range of sizes. The results of the experimental study can help designers select the optimal design of vents and cavities for the chosen AM technology, e.g., for conformal cooling systems.