- Ramgopal Ramaraju

Thermal spray deposition is used as a near-net-shape manufacturing process to make heat transfer devices, such as cold plates used to cool electronic devices. Channels were milled on the surface of aluminum or copper plates and inserts, made by 3D printing with a water-soluble polymer, were placed in them.  A layer of molten metal (2-3 mm thick) was sprayed on the surfaces of the plates using a twin wire arc system so that the channels were completely buried. The polymer inserts were dissolved, leaving the channels open for coolant flow. Using this method, devices such as cold plates and compact heat exchangers can be made.