Oh so much to cover (I go away for one day, and so much activity!!!). I'll tackle in varying order.
As for the die material: I have to consider what's commonly available, so I refer to our sponsor:
http://www.onlinemetals.com/index.cfm?affiliate_id=302
(link from Main page)
- Invar (an alloy of 36% nickel and 64% iron)
- Nickel Alloy R405 (similar to Monel)
- Titanium
- Tool steel (including "ALLOY 1018")
- Stainless
Maybe dubious purity, would not care to see 392, 396, 400 debated again.
My concern however is with the maintenance. Was thinking about some type of plating followed by a grind to restore die to same total height. The idea still needs thought, but all in all, copper's softness is a problem.
Damage to the heat die could be avoided/minimized with a proper mounting plate that would have "guides", but without interfering (significantly) with the final alignment. The damage expected would be a rounding of the contact area's edges.
As for dimensions, if we "stretch" (!) the Jedec 85% uniformity requirement to 85% of actual die size, then 12 by 12 mm will not do (extended, 12 by 12 is useless, see below).
I've gathered many actual core dimensions (a hard exercise!) but found most of the info at geek.com . For Intel, excluding the old Willamette core, core sizes vary between 112 mm2 and 237 mm2. That means using two dies, 10 by 10mm and 14 by 14mm, which actually does cover every core, within 15%. I have not collected all data for AMD.
Below is the collected data, complete with source links:
"CPU core dims and power"
Intel:
Smithfield 90nm
206 mm2 / 95 to 130 Watts
from THG
Prescott 2M 90nm
135 mm2 / 84 to 115W
from:
http://www.digital-daily.com/cpu/intel-prescott-2m/
Gallatin 130nm
237 mm2 / 54 to 97 W
from:
http://www.geek.com/procspec/intel/p7server_13_4.htm
Prescott 90nm
112 mm2
from:
http://www.extremetech.com/article2/...1478683,00.asp
103W
from:
http://techreport.com/reviews/2004q1...t/index.x?pg=2
Northwood 130nm
131 mm2 / 61 to 68W
from:
http://www.geek.com/procspec/intel/northwood.htm
Willamette 180nm
217 mm2
from:
http://www.geek.com/procspec/intel/p7consumer.htm
52 to 72W
from:
http://www.cpuscorecard.com/cpuprices/ip4.htm
AMD:
Toledo/Manchester 90nm
San Diego 90nm
115 mm2 / 104 W
from:
http://www.tomshardware.com/cpu/2005...n_fx57-02.html
Clawhammer 130nm
Venice 90nm
Newcastle 130nm
Winchester 90nm
Sledgehammer 130nm
Clawhammer 130nm
Clawhammer old 130nm
Newcastle 130nm
Paris 130nm
Palermo 90nm
Thoroughbred B 130nm
Thoroughbred A 130nm
Barton 130nm
Thorton 130nm