Development of sintering processes for the construction of aluminum heat sinks

The drive electronics are a key component for electric vehicles. So-called direct liquid-cooled power modules are used for the drive power. For good cooling performance, copper radiators with copper water cooling fins are the state of the art. However, a new phenomenon is occurring here: Contact corrosion between the water-cooled drive motor with the aluminum stator and the copper-cooled power module located in the same cooling circuit. This corrosion degradation process is to be remedied in the overall KoKo-Power project. To this end, this sub-project is developing a concept and a design for corrosion-compatible use in electric vehicles for drive electronics using aluminum heat sinks. The aim is a drive module that is realized with water-contacting, 3D-structured aluminium elements and a ceramic substrate by low-temperature sintering on the basis of silver. This replaces the classic copper heat sink with an aluminum body.