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Sound technical content, curated with aloha by
Ted Mooney, P.E. RET
Pine Beach, NJ

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Electroless Nickel vs Bare Aluminum: Thermal Performance

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Q. Hi. Came here for expert knowledge.

I have a question regarding the impact of electroless nickel finish - and the impact upon thermal conductivity.

I'm doing a thermal analysis of an electronic enclosure. Due to our industry we coat Aluminum 6061 with EN plating. So, I performed a search on the nets regarding the difference between bare AL and AL w/EN coating and how to account for this in my simulation. I couldn't find much. I did find the thermal conductivity of EN is 0.0135 cal/cm/sec/°C or equivalent to 5.6484 W/mK. AL is 237 W/mK. So, by adding EN coating does the thermal performance drop off significantly? Or does the minimal thickness of the EN coating not impact thermal performance at all? How do I account for EN AL in FEA if EN does impact performance? Thanks.

OHara
- Newtown Pennsylvania USA
July 25, 2024

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A. Hi OHara,
Thermal analysis is difficult, involving natural convection, forced convection, and radiation (emissivity), plus, as you bring up, the thermal conductivity of the surface finish. It's complicated enough that actual measurements are often done rather than relying only on theory.

I don't know too much about it, but do know that even heatsinks -- whose purpose is to dissipate heat -- are very frequently electroless nickel plated; so I am confident that the thermal conductivity of the electroless nickel coating is not an issue with severe deleterious impact on the heat transfer.

Bare aluminum has little corrosion resistance, is not solderable, and is not a reliable ground, if any of that matters for the appliction.

Luck & Regards,

ted_yosem
Ted Mooney, P.E. RET
Striving to live Aloha
finishing.com - Pine Beach, New Jersey

Thanks Ted.

From other posts on Finishing.com - I think the coating thickness is so thin it is nonconsequential for thermal conductivity. I thought I would at least ask - maybe there is a revelation that I may have overlooked. Besides I like to learn.

Ohara [returning]
- Newtown Pennsylvania USA
July 25, 2024

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