Aluminium/Silicon alloy (Al96/Si4) is a lightweight, thermally conductive material widely used in automotive, aerospace, and electronic industries. Its balance of mechanical strength, corrosion resistance, and excellent casting properties makes it an ideal choice for components where heat dissipation and dimensional stability are essential.
Material Overview
Al96/Si4 is a hypoeutectic aluminium-silicon alloy containing approximately 4 wt% Si. The silicon addition refines the microstructure, improving castability and reducing shrinkage porosity. The alloy’s microstructure consists of an aluminium-rich matrix with evenly distributed silicon particles, which enhance hardness and wear resistance. Studies on Al–Si alloys show that the presence of fine Si particles significantly lowers the coefficient of thermal expansion (CTE) while maintaining high thermal conductivity values ranging from 145 to 180 W/m·K (Cai et al., 2015). Additionally, the rapid solidification and powder metallurgy processing routes help achieve near pore-free microstructures with increased bending strength and fatigue resistance. The material’s typical yield strength ranges between 90–120 MPa, with an elongation of around 8–10%, depending on processing and heat treatment conditions (Ma et al., 2017).
Applications and Advantages
Due to its excellent thermal conductivity and low density, Al96/Si4 is widely used for electronic heat sinks, automotive pistons, and engine cylinder heads. Its silicon phase provides superior wear resistance, allowing long-term service in frictional or high-temperature environments. The alloy’s dimensional stability also makes it a preferred choice in optical housings, compressor bodies, and aerospace structures where precision and reliability are paramount. Research into semi-solid die casting (Hu et al., 2021) demonstrates that fine, globular microstructures enhance both mechanical performance and heat dissipation efficiency, improving fatigue life in thermally cycled components. The material’s recyclability and compatibility with additive manufacturing further strengthen its appeal for sustainable production and design optimization.
Goodfellow Availability
Goodfellow supplies Aluminium/Silicon alloy (Al96/Si4) in research-grade purity and customizable powder or solid forms. It is available for prototyping, advanced alloy development, and thermal management applications. Custom dimensions and specifications are supported to meet specialized engineering or academic requirements.
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References
- Cai, Z., Zhang, C., Wang, R., Peng, C., Qiu, K., & Feng, Y. (2015). Preparation of Al–Si alloys by a rapid solidification and powder metallurgy route. Materials & Design, 88, 1072–1079. https://doi.org/10.1016/j.matdes.2015.08.106
- Ma, P., Jia, Y., Prashanth, K. G., Yu, Z., Li, C., Zhao, J., Yang, S., & Lixin, H. (2017). Effect of Si content on the microstructure and properties of Al–Si alloys fabricated using hot extrusion. Journal of Materials Research, 32(13), 2525–2533. https://doi.org/10.1557/JMR.2017.97
- Hu, Z., Wang, X., Chen, X., Huan, P. C., Li, W., & Nagaumi, H. (2021). Study on microstructure and thermal conductivity of semi-solid die casting aluminum alloy. E3S Web of Conferences, 268, 01076. https://doi.org/10.1051/e3sconf/202126801076