Aluminum Alloy Composition Balancing Thermal Conductivity and Strength
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Solution Overview
Problem
Conventional aluminum alloys struggle to meet the demands of high thermal conductivity and mechanical strength required for miniaturized electronic and electrical products, while also being cost-effective and recyclable.
Innovation Solution
A thermally conductive aluminum alloy composition containing specific alloying elements (Si, Fe, Mg, Zn, Mn, Sr, Cu) with controlled impurities, achieving a thermal conductivity of at least 150 W/(m•K) and mechanical properties like tensile strength of 250 MPa, yield strength of 150 MPa, and elongation of 3.5%, with good flow forming properties and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional aluminum alloy materials (such as ADC12) are used, then the material is cost-effective and has good mechanical properties, but the thermal conductivity is only 96 W/(m•K) which is insufficient for miniaturized electronic products
Solution Approach 1:
The patent applies parameter changes by precisely controlling the chemical composition parameters of the aluminum alloy, specifically limiting Si to 5.0-11.0 wt%, Fe to 0.4-1.0 wt%, Mg to 0.2-1.0 wt%, and other elements to less than 0.1 wt% each. This compositional parameter optimization achieves a breakthrough in thermal conductivity (≥150 W/(m•K)) while maintaining mechanical strength (tensile strength ≥250 MPa, yield strength ≥150 MPa), resolving the contradiction between thermal and mechanical properties.
2Temperature
If alloying elements are added to improve thermal conductivity, then thermal conductivity increases, but the complexity of material composition and manufacturing process increases
Solution Approach 1:
The patent extracts and eliminates unnecessary alloying elements from the traditional aluminum alloy composition. By removing elements like Ni, Cr, Mo, and others that do not contribute significantly to thermal conductivity, and strictly limiting the content of common alloying elements (Si, Fe, Mg, Zn, Mn, Sr, Cu to less than 0.1 wt% each), the patent simplifies the material composition while achieving high thermal conductivity (≥150 W/(m•K)), thus resolving the contradiction between performance improvement and complexity increase.
3Temperature
If high thermal conductivity aluminum alloy is developed, then thermal management performance improves, but the cost of material development and production increases
Solution Approach 1:
The patent adopts a cost-effective approach by using common, inexpensive alloying elements (Si, Fe, Mg, Zn, Mn, Sr, Cu) with strictly controlled low content (each less than 0.1 wt%), rather than employing rare or expensive elements. This compositional strategy achieves high thermal conductivity (≥150 W/(m•K)) while maintaining production cost-effectiveness, resolving the contradiction between performance and manufacturing cost.
Data Source
AI summary
The present disclosure discloses a thermally conductive aluminum alloy and application thereof. The thermally conductive aluminum alloy contains alloying elements, unavoidable impurities and the balance of an aluminum element. Based on the total weight of the thermally conductive aluminum alloy, the alloying elements include: 5.0 to 11.0 wt% of Si, 0.4 to 1.0 wt% of Fe, 0.2 to 1.0 wt% of Mg, less than 0.1 wt% of Zn, less than 0.1 wt% of Mn, less than 0.1 wt% of Sr and less than 0.1 wt% of Cu. The thermally conductive aluminum alloy prepared by the present disclosure has a tensile strength of not less than 250 MPa, a yield strength of not less than 150 MPa, an elongation of not less than 3.5%, and a thermal conductivity of not less than 150 W/(m•K).