International Journal of Advanced Engineering Application

Investigating Perforated Heat Sink Using Recycled Cast Blocks for Enhanced Thermal Performance

Author(s):Aaradhya Jain¹, Hitendra Vaishnav²

Affiliation: 1Charterhouse School, Surrey, UK

Page No: 1-14

Volume issue & Publishing Year: Volume 2 Issue 12 , Dec-2025

Journal: International Journal of Advanced Engineering Application (IJAEA)

ISSN NO: 3048-6807

DOI: https://doi.org/10.5281/zenodo.17949205

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Abstract:
Effective thermal management has become increasingly important in modern electronic applications due to the increase in power densities and the reduction in the size of components, which requires more exotic heat dissipating technologies to guarantee system reliability and lifespan. Heat sinks remain the leading form of passive cooling, where the complexity of the fin design must be increased to maximize the effectiveness of convective heat transfer. This research investigates whether a perforated heat sink made from recycled aluminum waste can provide improvements in the thermal management of electronics. In particular, it examines whether heat sinks made with circular perforated holes in an overall block of recycled metal will have comparable thermal performance to conventional heat sinks machined from raw metal stock. The results of the experiments are verified and supplemented with detailed ANSYS simulations showing the heat transfer, fluid flow, and temperature distributions of both perforated and slab heat sink geometries under realistic boundary conditions and material properties. The results show that the recycled perforated heat sinks have thermal efficiencies similar to the solid heat sinks, although the temperature gradients and heat dissipation patterns varied slightly. Utilizing recycled aluminum reduces material costs and environmental impacts, and demonstrates the value of sustainable manufacturing processes applied to thermal management systems.

Keywords: Heat Sinks, Circular perforation fins, Heat transfer enhancement, Performance analysis

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