- Aluminum Advantages: Lower Cost (material and processing). Lower Density (lighter weight – ~2.7 g/cm³ vs. 8.9 g/cm³ for Cu). Easier to Extrude into complex fin shapes. Good thermal conductivity (~200-230 W/m·K for alloys).
- Copper Advantages: Higher Thermal Conductivity (~400 W/m·K), nearly double that of aluminum. This makes it superior for heat spreading. Better Solderability for attaching fins or pipes.
- Comparison: Pure aluminum is rarely used; alloys like 6063 balance strength and conductivity. Copper is used where maximum performance is critical, especially in the base of high-end coolers or for small, dense heat spreaders. The copper-aluminum composite design is common: a copper base (or heat pipes) for rapid heat absorption/spreading, married to aluminum fins (for cost-effective, lightweight dissipation).