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There's a whitepaper available here http://prod.sandia.gov/techlib/access-control.cgi/2010/10025...

Their data suggests that the air gap provides minimal resistance to the flow of heat. As for the clearance, they've stated that unusually high-precision manufacturing is not required for the two surfaces.



Re: clearance, while .001" clearance isn't something I'd want in a design particularly, modern machine tools are good enough that you get flatness and surface finish good enough to not have problems at .001" clearance basically free on any machined surface.




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