Tailoring thermal conductivity and microstructure of Al–Fe alloys by addition of Sc2O3 and variable cooling rates

Al–Fe alloy is a kind of high thermal conductivity alloy, which are widely utilized in the communication and automobile industries. The thermal conductivity is greatly affected by the morphology, size, and distribution of iron-rich intermetallic phases (Fe-rich phases), pores, and Al grains. The evolution of microstructure and thermal conductivity of Al–Fe alloys by adding Sc2O3 particles and adjusting cooling rates are systematically studied by optical and scanning electron microscopy, and synchrotron X-ray imaging. The results show that Sc2O3 addition reduces the size and increases the number of primary Fe-rich phases, while increasing the grain size of Al matrix. The Sc2O3 promote their nucleation of primary Fe-rich phases and partial Sc solutes inhibit their growth, resulting in the improvement of thermal conductivity and mechanical properties. The remaining Sc2O3 particles have large lattice misfit with Al, led to the formation of coarsen size Al. The highest thermal conductivity is 214 W/(m·K) in the alloy with Sc2O3 and slow cooling rate. Sc2O3 addition increase the thermal conductivity of the studied alloys, i.e., an increment of 3 W/(m K) (by 1.1 %) at slow cooling rate by and an increment of 11 W/(m K) (by 6.2 %) at fast cooling rate. This study provides a new strategy to improving thermal conductivity of Al alloy for both academia and industry.