Originally posted by: BonzaiDuck
AigoMorla
I wanted to keep the lid on this until I can see how well it works, but you've provoked me.
Yes, the mainstream ways of "modding" the U-120 or Extreme involve grinding away the ridge-line in TR's conscious design-decision to make a convex heatsink base. TR tech-reps "Bob" and "Hank Peng" told me they chose to do this because it was felt that the heatsink base only needed to make contact with the heat-spreader where the two processor cores resided. However, the concept of thermal resistance also includes a factor of areal-size, so instead of measuring it as just C-degrees / thermal-Watts, it is sometimes expressed as:
TR = C / (m^2 * W)
or in square centimeters, or square inches. Since processor sizes have shrunk, this has been an emerging issue in using TEC plates and in the effectiveness of TIM or thermal greases.
Since the heat would spread over the heatspreader-cap, even as it is being wicked away by the Ultra-120 convex base, it would seem that the thermal resistance of the heatspreader itself would be a factor in some of that heat continuing to spread over the heatspreader to warm it up a tad, so more comprehensive contact with the heatspreader may have some positive effect on temperatures and thermal resistance overall.
Because it might be prefered to build a jig to lap the base well and consistently (given its irregular shape to begin with) -- a jig that might be made from small lengths of hardwood -- and because I discovered that SVC is offering a "custom-lapped" U-120-Extreme for $30 more, I decided simply to "outsource" the lapping to them.
We discussed it over the phone. It took them a day or so to define for themselves how to build a jig so they could do it swiftly and accurately. They take off one millimeter at the ridge-line, or high-point on the base.
This of course leaves a mirror-polished copper surface. TR stipulates that their warranty is voided if you grind away the nickel-plate, which, they say, insures the "integrity" of the solder-joints between the heat-pipes and the base. I discussed this with the SVC tech-rep, and we mutually came to the conclusion that there is a chance -- eventually -- of corrosion around the edge of the nickel-plate where the copper is exposed, risking that the nickel might begin to peel away. But one could simply put a thin layer of thermal epoxy around that boundary to prevent such things from happening.
My friend across town bought the U-120-Extreme I had waiting in the retail box before I purchased a custom-lapped cooler from SVC, so no loss . . . .
But here is the basis of some improvements I intend to make:
January, '07 OverClocker's article
One reseller's current offering, about equal to AS5
[With 10% content, the Taiwanese company is hoping to minimize cost, capture more mainstream consumers, and take away Arctic Silver's market, since their formulation barely keeps up with AS5.]
One of several suppliers whose traditional customers work with cutting wheels and machinery
"Grit #1," their finest powder, is graded at a particulate-size of less than 2 microns, and the distribution of particle sizes ranges from 0 to 2 microns. If the particle sizes are normally or horizontally distributed, then figure an average particle-size of 1 micron -- or 0.00004 inches. By comparison, the size of silver particles in AS5 ranges between 0 and 0.49 microns. This is not a big difference in average particulate-size.
WHAT THAT MEANS, IN COMPARISON TO Arctic Silver's OWN BENCH-TESTS
AS rates their AS5 compound on a controlled application of the paste with a thickness of 0.001 inch. This would be equivalent to piling 25 1-micron "abrasive" particles on top of each other.
COST
$4 per carat; 5 carats per gram.
Minimum order-quantity = 5 grams.
I'll report on the coverage, but I have plans to split my order with one other person. If there is ample dust left over, then it will be split three ways -- participants already chosen.
SECOND-BEST ADDITIONS OF COMPLEXITY
http://www.overclockers.com/tips188/
Two months ago, I visited a handicapped friend to assist in setting up shared internet access so that his caretaker-brother could perform shopping and other tasks on the web without interrupting my friend's efforts at writing a comic-crime-novel using Dragon Naturally Speaking. I was rewarded with a brand-new 2007 US Mint-issue silver dollar -- 99.9% "fine silver." I emphatically stated that I wasn't a coin-collector, and that I was immensely grateful, intending to put the item to good use.
Remember that SVC grates off 1-millimeter of the U-120-Extreme's heatsink base. I share a view with others that adding 2.96 millimeters of soft metal to the bottom of the base is not going to add too much in pressure resulting from further compression of the mounting-screw springs, but consider this. The "Lady Liberty," Bald Eagle, raised-rim and raised-printing on the coin have a depth of about 0.35 mm. [I splurged to add a digital caliper/micrometer with depth-gauge to my tool-collection.] That means that lapping should result in removal of at least 0.70 mm, leaving a slug that is approximately 2.26 mm thick. Subtract the 1mm removed by SVC, and we're adding 1.26mm (or less) to the heatsink base.
But what good does this do? It adds, at most, 30 grams of weight to the heatsink base with virtually no increase in torque against the motherboard. This would mean that the resulting "composite base" now has an overall thermal resistance component that is lower. But the increase in weight is only about 3/80 or about 4%. Second, it introduces another thermal interface, where there was previously only one. It hardly seems worth it. But wait!
Of the two substances, copper and silver, they are both "malleable," but silver is the softer of the two (I believe). Suppose, then, that you either "roll" the slug into a 1mm thickness (providing enough of it to use on graphics cards, etc.) or just stick it between two, polished, flat hard-steel plates, put the sandwich on an anvil, and pound it a little, apply the digital caliper, pound some more . . . etc.? But then again, what good does THAT do?
Add a fraction of a gram of the abrasive powder to one of the steel plates; spread it around on an area equal to the area of the silver slug; lay the slug on top of the dust (carefully, so your $4/carat investment doesn't get "blown away"); add the other plate; put it on an anvil; give it a couple of light taps.
Then, the calculating risk-taker has two choices: load up some CK4800 paste with more abrasive powder, and assume that the pressure between the heatsink-base and the processor cap is sufficient to keep the slug in place (risk #1); or mix some more powder with one component of either ASTA thermal epoxy, or Arctic Alumina epoxy, and then mix the epoxy, spread it on the heatsink base thinly, get the slug on the paste before it's too late (risk #2), and clamp it with some very small clamps, thus making it impossible to return the Ultra-120-Extreme to its previous "retail-package" state if things don't "work out well" (risk #3).
Of course, one could always use some Gorilla Glue beads to secure the slug to the heatsink base after applying a 50%-abrasive (my code-word for . . . you know . . ) enhancement to CK4800 or AS3 or just regular ThermalRight thermal grease.
Here are the relative thermal conductivities of copper, silver . . . and, ah . . . . abrasive powder:
Cu = 400
Ag = 430
"crystal Carbon" = 1000 to 2000 (another code-word )
One would think that the third item would simply make "thermal interfaces" disappear in the relative sense of thermal resistance and thermal conductivity. Further, the Ag shim just becomes a vehicle for applying more "crystal dust," so only a 1mm shim would be necessary.
My local coin dealer sells 2 gram ingots of Silver for $1 each -- they're about a millimeter thick, and could be "rolled" or pounded into a thickness of 0.5 mm. So you don't even need to destroy a $35+ collector's item for its silver-content.
That leaves my "ducting" mod, and I'm going to cut and fit the panels over the next week or two. Which means, in turn, if you want to wait and see how this all turns out, you'll just have to wait . . .
Otherwise, for you risk-takers and spend-thrifts, don't e-mail Penn-Scientific -- call them. Ask for "Diane." They take credit-cards. She is also very pleasant to talk to.
For me, a vial of white-powder arrives by mail in the next few days.
And that's not something anyone would want to snort up their nose, either!
SUMMARY EMPHASIS
Recent news and white-papers in the industry point to the thermal interface between heatsink (or water-block -- Yeah, Aigomorla, Yeah!!) as critical to the future of the industry and to the future of us "enthusiasts." A lady professor at a prestigious university has shown that carbon-black can be made to surpass thermal resistance and conductivity properties of silver and other paste-components (with our "abrasive" exception), but the pressure needed to make it work is far too great for current heatsink applications (and for the life or operability of our expensive components).
Now -- I have some questions. I believe that economic reasoning and strategy have limited the offering by JetArt to the 10% formulation. Yet I have not seen anyone else attempting to produce a retail TIM with the easily-reached limit of 2.5 times the thermal conductivity of AS5. Citarella estimates the cost of a well-loaded TIM using the abrasive substance in question at about $50 for 10 applications.
What am I missing here? Or is this just something that has been "overlooked" in "the community?"
We're gonna find out soon.