Overview
The XL4015 buck converter module is ubiquitous on AliExpress, promising 5A output at prices under $2. Our testing reveals significant gaps between marketing claims and real-world performance.
Thermal Analysis
Thermal Warning
At 5A output, the XL4015 IC reaches 95°C within 5 minutes without additional heatsinking. This exceeds safe operating limits.
Temperature vs Load (25°C ambient, no heatsink)
| Load Current | IC Temperature | Inductor Temp |
|---|---|---|
| 1A | 45°C | 35°C |
| 2A | 58°C | 48°C |
| 3A | 72°C | 62°C |
| 4A | 85°C | 75°C |
| 5A | 95°C+ | 85°C |
Component Quality Issues
Teardown of 5 modules revealed:
- Capacitors: Marked as 100µF/50V, actual capacitance measured 60-80µF
- Inductor: Adequate for 3A, saturates at higher currents
- Diode: SS54 Schottky appears genuine
- IC: XL4015 marking consistent, likely authentic
Safe Operating Recommendations
For reliable operation:
max_continuous_current: 3A
recommended_with_heatsink: 4A
input_output_differential: ">3V for efficiency"
ambient_temperature: "<40°C"Modifications for Better Performance
- Add heatsink: Aluminum plate or finned heatsink on IC
- Replace capacitors: Use quality 105°C rated electrolytics
- Improve airflow: Add small fan for >3A loads
- Add input capacitor: Extra 470µF for input stability