Manufacturing Cost Reduction for Key Enabling Thermal Management Applications Using CTE Controlled Graphite Fiber Reinforced Al

Thermal expansion can be designed into a graphite fiber reinforced Al or Cu composite over a range of 2 to 10 ppm/K by controlling the fiber architecture an volume loading. Discontinuous graphite fibers have been arranged into a random in-planearchitecture to produce planar isotropic properties with a low standard deviation. Six different combinations of fiber type, fiber manufacturer and preform architecture were evaluated. A planar-isotropic arrangement of chopped and milled fibers resultsin the best combination of properties and process economics. Cost models have been developed and a commercialization strategy has been devised to provide low cost high thermal conductivity CTE matched heat sinks for advanced MDA and DoD applications.Featured in the Phase II program are low cost preform technology, cost reductions in fiber procurement and more precise CTE matching to high power wide band gap amplifiers (SiC and GaN) as well as legacy GaAs and Si devices. Manufacturing andproducibility studies will concentrate on facilities enhancements and product reliability. Materials enhancements such as corrosion resistance and hermetic behavior are addressed. The customer will be presented with a wide range of thermal managementsolutions based upon graphite Al and graphite Cu composites.