1. Mechanical Strength Degradation
Yield Strength Reduction: Aluminum alloys experience a significant drop in yield strength at temperatures above 150°C, compromising structural stability35.
Creep Resistance: Prolonged exposure to temperatures exceeding 200°C accelerates creep deformation, especially in non-heat-treated alloys7.
2. Thermal Expansion Challenges
Dimensional Instability: High thermal expansion coefficients (≈23×10⁻⁶/°C) induce stress mismatches in multi-material systems, leading to warping or joint failure67.
3. Oxidation and Corrosion
Surface Oxidation: Above 400°C, accelerated oxide layer formation weakens fatigue resistance and promotes microcrack initiation57.
Chloride Sensitivity: In coastal or industrial high-heat zones, chloride-induced pitting corrosion exacerbates material degradation6.
4. Electrical and Thermal Conductivity Impacts
Thermal Runaway Risk: In electronic systems, aluminum's high thermal conductivity can transfer heat to adjacent components, destabilizing temperature-sensitive parts like batteries38.
Resistivity Increase: Elevated temperatures reduce electrical conductivity by up to 30%, affecting busbar efficiency in power systems8.
5. Application-Specific Limitations
Solar Energy Systems: Aluminum framing in PV modules requires additional thermal shielding to mitigate efficiency losses from heat-induced expansion5.
Aerospace Constraints: Aluminum alloys are replaced by ceramic composites in engine components where temperatures exceed 300°C7.
Mitigation Strategies
Alloying Additives: Magnesium and silicon enhance high-temperature stability (e.g., 6061-T6 alloy)5
Thermal Barriers: Coatings like anodized layers or ceramic composites reduce heat absorption67.
Design Adjustments: Expansion joints and thermal isolation gaps compensate for dimensional changes
