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Modelling and optimization of aging parameters for thermal properties of Al 6082 alloy using

response surface methodology

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 Mater. Res. Express 4 (2017) 046502 https://doi.org/10.1088/2053-1591/aa68c1

PAPER

Modelling and optimization of aging parameters for thermal

properties of Al 6082 alloy using response surface methodology
RECEIVED
15 February 2017
RE VISED
14 March 2017
ACCEP TED FOR PUBLICATION
Devendra Kumar Vishwakarma, Narendra Kumar and Aditya Kumar Padap
23 March 2017 Department of Mechanical Engineering, B.I.E.T, Jhansi 284128, India
PUBLISHED E-mail: narendra.dharwan@gmail.com
12 April 2017
Keywords: Al 6082 alloy, aging, RSM, thermal conductivity, CTE

Abstract
In the present paper an effort is made to study the effect of aging parameters solution time, aging
temperature and aging time on thermal conductivity and coefficient of thermal expansion (CTE) of
Al 6082 alloy by using central composite rotatable design (CCRD) of response surface methodology
(RSM). Three different parameters at five levels each are chosen for the experimentation. A second
order polynomial mathematical model is developed for thermal conductivity and CTE to study
the main and interactive effect of parameters on thermal conductivity and coefficient of thermal
expansion. The aging parameters are also optimised for the optimum value of thermal properties.
The results reveal that aging temperature is most significant parameter for change in thermal
conductivity and CTE followed by aging time and solution time. Thermal conductivity and
coefficient of thermal expansion has been improved by 17% and 20% respectively as compared
as-received alloy. The improvement in thermal properties is attributed to the precipitation of Mg2Si
particles in the alloy matrix.

1. Introduction

Al 6082 is an aluminium–magnesium–silicon family (6xxx series) alloy. It has been widely used in many sectors
such as automobile, aircraft, marine and construction, owing to its low cost, high strength to weight ratio, good
formability, weldabilty, excellent corrosion resistance, and higher thermal conductivity [1–5]. Properties of this
alloy can be monitored by using different processes such as heat treatment, preparing composites and severe
plastic deformation [6–9]. Many researchers have worked to improve the mechanical and thermal properties
of this alloy. Choi et al [1] reported 3.4 % increase in the thermal conductivity of Al–9.7Si–0.7Cu–0.4Mg alloy
due to aging treatment for a time period of 1–10 h in temperature range of 180–190 °C. Choi et al [2] observed
that the increase in thermal conductivity and thermal diffusivity is due to the absorption of solute atoms into
the aluminium matrix during intermetallic phase precipitation. Sharma et al [3] investigate the dry sliding
behaviour of Al 6082/Gr metal matrix composite by using RSM. They observed the decrease in microhardness
and macrohardness of Al 6082 composite with increase in amount of graphite particles. Dadbakhsh et al [6]
studied the effect of aging treatment and equal channel angular pressing (ECAP) process on the strength of Al
6082 alloy. They observed the enhanced strength of Al 6082 alloy by ECAP before and after the aging treatment.
Ductility was also reported to be increased in their study. Ma et al [7] studied the influence of solution heat
treatment (SHT) on mechanical and fracture behaviour of Al 6082 using RSM. It was reported that SHT time
and temperature significantly affect the properties and fracture morphology of alloy. Prabhukhot & Prasad
[8] investigate the effect of heat treatment on the hardness of Al 6082- T6 alloy and reported the changes in
grain size and grain structure during solution heat treatment and artificial aging process. These changes are
responsible for reduction in hardness of alloy. Garrett et al [9] studied the effects of solution heat treatment
(SHT) time on the mechanical properties of 6082 alloy for a range of deformation rates at the SHT temperature of
525 °C. They reported increased ductility with increasing SHT time, however, maximum flow stress shows reverse
trend. Mrówka-Nowotnik et al [10] studied the effect of heat treatment parameters on the tensile properties
and fracture toughness of Al 6082 alloy and observed a continuous increase in tensile strength, with increasing
aging time, however no significant change was observed in elongation. Gandra et al [11] studied the influence of

© 2017 IOP Publishing Ltd

Mater. Res. Express 4 (2017) 046502 D K Vishwakarma et al

Table 1.  Composition of Al 6082 alloy.

Elements Cu Mg Si Fe Mn Cr Al

wt.% 0.025 0.97 1.02 0.18 0.42 0.03 Remainder

Table 2.  Aging parameters and their levels.

Levels

Parameters Notation Units −1.682 −1 0 1 1.682

Solution time A h 1 2 3 4 5
Aging temperature B °C 130 150 170 190 210
Aging time C h 1.5 3.0 4.5 6.0 7.5

process parameters, axial force, rotation and travel speed in the friction surfacing of AA 6082-T6 over AA 2024-T3
alloy. They reported in their study that low travel and rotation speeds were responsible for increasing the coating
thickness and width. Cabibbo et al [12] studied the effect of severe plastic deformation on the secondary phase
precipitation of Al 6082 alloy and observed the increase in hardness of alloy is due to grain refinement. El-Danaf
et al [13] investigated the effect of high pressure torsion on microstructure and mechanical properties of Al 6082
alloy. They observed increased hardness of Al 6082 alloy for both T651annealed condition and solution treatment
followed by over aging and ECAP process. El-Danaf and El-Rayes [14] investigated the microstructure and
mechanical properties of friction stir welded of Al 6082 alloy with respect to the number of passes and traverse
speeds. They observed that dynamic recrystallization of the stir zone takes place due to friction stir processing
which results into the generating equiaxed grains with high angle grain boundaries. The equiaxed grains were
found to be increased with increasing the number of passes; however the increased traverse speed has no effect on
grain size. Moreover tensile strength and hardness get reduced with increased number of passes whereas reverse
trend is observed with increased traverse speed. Vemvu and Ganesan [15] developed a mathematical model to
optimise the heat treatment process parameters, solutionizing time, aging temperature, and aging time for tensile
strength and ductility of aluminium silicon carbide particulate composite. They reported that solutionizing time
has more influence on tensile strength as compared to other parameters.
In view of the literature studied, it has been found that many reports are available on improvement in mechani-
cal properties of Al 6082 alloy. In addition to mechanical properties, thermal conductivity is an important property
which plays an important role for high temperature automotive applications. During the combustion process in
IC engine high temperature is generated inside the cylinder head due to which cylinder walls are affected from
thermal stresses and hot spots. In order to avoid the surface from thermal damage the generated heat should be
removed very quickly which is possible only from high thermal conductivity alloy. Higher the thermal conductiv-
ity, faster the heat extraction which results into improved life of components. Moreover, thermal conductivity is
also important to estimate the life time of components. Therefore, to be a potential candidate for the engine comp­
onents, the studies on the thermal conductivity are very essential [1, 2, 16]. Coefficient of thermal expansion study
is useful to reveal the presence of the residual thermal stresses generated in the alloy. These residual thermal stresses
are produced by sudden quenching of alloy after solutionizing. These are also affects by aging time and study is
also necessary for high-temperature applications of alloy [17]. It is also reported in literature that precipitation of
phases during artificial aging treatment enhances the thermal properties of alloys [2, 18].
Therefore, the main objective of the present study is to describe and examine the way to enhance the thermal
properties of the 6082 alloy after aging treatment. The mathematical model equations are also derived to obtain
optimum thermal properties. Moreover, correlation between the thermal properties and microstructure is also
discussed in the present study.

2.  Experimental procedures

Al 6082 alloy in the form of rod, diameter 25 mm is used as raw material in the present study and chemical
composition is shown in table 1.The samples are prepared with the dimensions 25 mm diameter and 2.5 mm
thickness. All the prepared samples are solutionized in muffle furnace at 450 °C for a period of 1–5 h followed by
water quenching at room temperature. The samples were then aged in the temperature range of 130–210 °C for a
period of 1.5–7.5 h followed by natural cooling at room temperature.
The thermal conductivity of each sample is tested on TCi thermal conductivity analyser (C-THERM) using
modified transient plane source (MTPS) method. The Coefficient of thermal expansion is measured with the help
of 125MG Dual Grid Strain Gauges. Invar is used as reference material for testing. Optical microscopy of etched
samples was carried out by using optical microscope.

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Mater. Res. Express 4 (2017) 046502 D K Vishwakarma et al

Table 3.  Experimental results for thermal properties of Al 6082 alloy.

Aging parameters Thermal Thermal expansion

conductivity coefficient,
A B C
Experimental run (W m−1 K−1) CTE (×10−6 °C−1)

1 3 170 4.5 201 25

2 3 130 4.5 183 21
3 2 150 3.0 182 22
4 3 170 4.5 201 24
5 1 170 4.5 196 24
6 3 210 4.5 206 21
7 3 170 4.5 202 25
8 2 190 3.0 201 26
9 3 170 4.5 201 25
10 4 190 3.0 204 27
11 3 170 7.5 208 29
12 4 150 3.0 184 23
13 5 170 4.5 203 25
14 4 150 6.0 191 24
15 4 190 6.0 212 28
16 2 150 6.0 186 23
17 3 170 4.5 202 24
18 2 190 6.0 206 27
19 3 170 1.5 198 23
20 3 170 4.5 201 24

Table 4.  Analysis of variance for thermal conductivity.

Source DF Adj SS Adj MS F-value P-value % contribution

Model 9 1367.45 151.94 23.25 0.000 95.44

Linear 3 1209.84 403.28 61.71 0.000 84.44
Solution time 1 56.48 56.48 8.64 0.015 3.94
Aging temperature 1 1031.37 1031.37 157.82 0.000 71.98
Aging time 1 122.00 122.00 18.67 0.002 8.51
Square 3 152.11 50.70 7.76 0.006 10.62
2 way interaction 3 5.50 1.83 0.28 0.838 0.38
Error 10 65.35 6.53 4.56
Lack of fit 5 64.02 12.80 48.01 0.000 4.47
Pure error 5 1.33 0.27 0.09
Total 19 1432.80 100

3.  Development of mathematical models

3.1.  Response surface methodology (RSM)

In past time, experiments have to be repeated five to ten times to get better results which results into large number
of experiments to be performed. Lots of time and cost is required to perform and analyses the experimental
results. Therefore, there is an urgent need for designing the experiments. A well designed experimental plan can
substantially reduce the total number of experiments [19]. RSM is a statistical and mathematical technique used
for modeling and optimization of various responses, influenced by different process parameters [20]. A suitable
approximation for a functional relationship between dependent and independent parameters is developed in
RSM. Generally, second-order models are used in RSM because of their flexibility and wide variety of functional
forms. Moreover these models provide a good approximation to the true response surface [21–23]. A large number
of reports are available in literature on modeling and optimization using RSM [24–28]. These studies showed that
RSM can be an economical and effective method for optimization and modeling of various processes.

3.2.  Central composite rotatable design (CCRD)

Variety of experimental design techniques like Taguchi, full factorial, partial factorial and CCRD are used for
process optimization [29–31]. Among these CCRD is the most efficient experimental design, used extensively to
develop and optimize the second order response surface models [21, 22]. CCRD is originally developed by Box and

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Mater. Res. Express 4 (2017) 046502 D K Vishwakarma et al

Figure 1.  Scattered diagram of developed mathematical model for thermal conductivity.

Table 5.  Analysis of variance for coefficient of thermal expansion.

Source DF Adj SS Adj MS F-value P-value % contribution

Model 9 0 0 28.11 0.000 96.04

Linear 3 0 0 83.03 0.00 94.15
Solution time 1 0 0 8.43 0.016 3.19
Aging temp. 1 0 0 226.50 0.000 85.61
Aging time 1 0 0 14.16 0.004 5.35
Square 3 0 0 1.29 0.331 1.89
2 way interaction 3 0 0 0 1 0.00
Error 10 0 0 3.96
Lack of fit 5 0 0 1.10 0.458 1.94
Pure error 5 0 0 2.02
Total 19 0 100

Figure 2.  Scattered diagram for developed mathematical model for CTE.

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Mater. Res. Express 4 (2017) 046502 D K Vishwakarma et al

Figure 3.  Optical micrograph of aged Al 6082 alloy showing precipitation.

Figure 4.  XRD pattern of aged Al 6082 alloy.

Wilson [32] and improved upon by Box and Hunter [33]. CCRD experimental design establishes the mathematical
relation of the response surface using the least possible number of experiments without losing its accuracy. In
CCRD technique number of experiments to be performed is very less as compared to full factorial design and
has been proved to be sufficient to describe the majority of steady-state process responses [31, 34]. Therefore, in
the present study, CCRD technique is used to plan the experiments. The equation (1) shows the second-order
polynomial for the response surface methodology [35]
k k k
η = βo + ∑ βjx i + ∑ βjj x 2j + ∑ ∑ βijx ix j
(1)
j=1 j=1 i<j=2

where η is response; xi (1, 2, …, k) is the coded level of k quantitative variables; βo is the constant term, where βj, βjj,
and βij are the coefficients of the linear equation.
The number of experimental run required for CCRD consists of standard 2k factorial with its origin at the
center, 2k points fixed axially at a distance, β, from the center to generate the quadratic terms and replicate run at
the center; where k is the number of parameters. The axial points are chosen such that they allow rotatability [33],
which ensures that the variance of the model prediction is constant for all points equidistant from the design center.

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Mater. Res. Express 4 (2017) 046502 D K Vishwakarma et al

Figure 5.  Surface and contour plot showing variation of thermal conductivity with (a) solution time and aging time (b) solution
time and aging temperature and (c) aging temperature and aging time.

Replication of the test at center point is very important to give independent estimate of the experimental error [36,
37]. Table 2 represents the five different levels of process parameters and their ranges selected in the present study.
Twenty experiments are carried out according to CCRD technique and experimental results are collected as per
the experimental design matrix given in table 3.
For empirical mathematical modelling, a software package MINITAB 17 has been used to find out the coef-
ficients of mathematical modelling based on the response surface regression form. The mathematical relationship
obtained for thermal conductivity and CTE is given by equations (2) and (3)
Thermal Conductivity = 201.43 + 2.034 A + 8.690B + 2.989C − 1.304A ∗ A − 3.072B ∗ B
(2) − 0.067C ∗ C + 0.250A ∗ B + 0.750A ∗ C + 0.250B ∗ C
R2 =  95.44%
 
CTE = 0.000025 + 0.0A + 0.000002B + 0.000001C + 0.0A ∗ A + 0.0B ∗ B
 −0.0C ∗ C + 0.0A ∗ B − 0.0A ∗ C + 0.0B ∗ C
(3)
R2 = 96.20%

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Mater. Res. Express 4 (2017) 046502 D K Vishwakarma et al

Figure 6.  The main effect plot of thermal conductivity verses solution time, aging temperature and aging time.

3.3.  Analysis of thermal conductivity model

The developed model for thermal conductivity has R2  =  95.44% which indicates that the model is statically
significant at 95% confidence limit and provides a significant correlation between thermal conductivity and
various process parameters. In order to check the adequacy of developed model analysis of variance (ANOVA) is
performed for the fitted model and results are shown in table 4.The results reveal that p value is less than 0.05 for
model which clearly indicates that the fitted model can be measured statically considerable over a confidence level
of 95%. Aging temperature is the most dominant parameter for thermal conductivity with percentage contribution
of 71.98% followed by aging time with percentage contribution of 8.51% and solution time with contribution of
3.94%. It can also be observed from the table that the error between experimental value and predicted value is less
than 5%. Figure 1 shows the scatter diagram of developed model. The experimental values and predicted values
from the model are scattered both sides and close to 45° line, which further proves the adequacy of the model.

3.4.  Analysis of CTE model

The R-square value for CTE model is 96.20% which is an indication of adequacy of model and good correlation
between CTE and process parameters at 95% confidence limit. ANOVA results for the developed model are shown
in table 5. The results reveal the percentage contribution of each parameter which is responsible for the change in
CTE of Al 6082 alloy. It can be clearly observed that aging temperature is the main contributing parameter with
85.61% contribution followed by aging time (5.35%) and solution time with 3.19% contribution. It can also be
observed from the table that the error between experimental value and predicted value is less than 5%. Figure 2
shows the scatter diagram of developed model. The experimental values and predicted values from the model are
scattered both sides and close to 45° line, which further proves the adequacy of the model.

4.  Results and discussion

4.1.  Optical microscopy

Optical microscopy study is performed to reveal the presence of precipitates in the alloy matrix.The optical
micrograph (figure 3) show white patches of aluminium matrix and black patches of Mg2Si precipitates for
experimental run 15 (solution time, 4 h, aging temperature, 190 °C and aging time 6 h) condition.

4.2.  XRD study

XRD study is carried out for secondary confirmation of Mg2Si precipitares present in the aluminium matrix.
Figure 4 shows x-ray diffraction pattern of aged alloy sample tested at experimental run 4 which consist of
aluminium and Mg2Si diffraction peaks.

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Mater. Res. Express 4 (2017) 046502 D K Vishwakarma et al

Figure 7.  Surface and contour plot showing variation of CTE with (a) solution time and aging time (b) solution time and aging
temperature and (c) aging temperature and aging time.

4.3.  Effect of aging parameters on thermal conductivity

Surface and colour contour plots of variation in thermal conductivity of Al 6082 alloy with combination of process
parameters is shown in figures 5(a)–(c). It is clearly observed from the plots that thermal conductivity increases
with increase in all parameters, solution time, aging time and aging temperature however solution time effect is less
in thermal conductivity. The imrovemnt in thermal conductivity may be attributed to the increase in precipitation
of Mg2Si in the aluminum matrix as the aging process progresses. The precipitation of alloying elements present in
Al 6082 alloy reduces their amount in the solid solution and hence reduce the thermal barrier present in the alloy
which directly lead to the increase in thermal condcutivity of alloy. Cingi et al [38] also reported improvement in
the thermal conductivity due to reduced amount of alloying elements, Mg, Cu, and Si in solid solution. Main effect
plot for thermal conductivity with solution time, aging temperature and aging time is shown in figure 6.
4.4.  Effect of aging parameters on CTE
Surface and colour contour plots of variation in CTE of Al 6082 alloy with change in various parameters is shown
in figures 7(a)–(c). Continuous increase in CTE has been observed with increase in solution time, aging time and
aging temperature. The sudden quenching of alloy after solution time produces residual stresses in the alloy [17].
Residual stresses were increases with each heating and cooling cycle. These residual stresses were released when the

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Mater. Res. Express 4 (2017) 046502 D K Vishwakarma et al

Figure 8.  Main effect plot for CTE with solution time, aging temperature and aging time.

Figure 9.  (a) Optimum results for maximum thermal conductivity and (b) for maximum CTE.

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Mater. Res. Express 4 (2017) 046502 D K Vishwakarma et al

Table 6.  Optimum values of various parameters for thermal conductivity.

Parameters Optimum values Thermal conductivity (W m−1 K−1)

Solution time (h) 4 212

Aging temperature (°C) 190
Aging time (h) 7.5

Table 7.  Optimum values of various parameters for coefficient of thermal expansion.

Parameters Optimum values CTE (×10−6 °C−1)

Solution time (h) 5 29

Aging temperature (°C) 210
Aging time (h) 7.5

Table 8.  Confirmation test result for thermal conductivity with optimum value.

Parameters Optimum values Thermal conductivity (W m−1 K−1) Error (%)

Solution time (h) 4 214 1

Aging temperature (°C) 190
Aging time (h) 7.5

Table 9.  Confirmation test result for CTE with optimum value.

Parameters Optimum values Coefficient of thermal expansion (×10−6 °C−1) Error (%)

Solution time (h) 5 28 3.44

Aging temperature (°C) 210
Aging time (h) 7.5

alloy is subjected to aging treatment. The residual stresses present in Al 6082 alloy releases gradually when aging
temperature increases which leads to increase in CTE of Al 6082 after aging treatment. Main effect plot for CTE
with solution time, aging temperature and aging time is shown in figure 8.

5.  Analysis of optimization plot

The optimality searches has been done for both mathematical models, i.e. equations (2) and (3), for correlating
the aging parameters effects with the thermal conductivity and CTE. Optimal combination of aging parameters
and their combined effect on the desired response criteria is ibtained by optimality analysis. Figures 9(a) and (b)
shows that the optimality analysis plots for thermal conductivity and CTE and optimized conditions are tabulated
in tables 6 and 7 respectively.

6.  Confirmatory test

Confirmatory tests are performed by using the optimum conditions to check the adequacy of the model for
predicting the maximum thermal conductivity and coefficient of thermal expansion. Maximum values of thermal
conductivity and CTE were obtained as 214 W m−1 K−1 and 28  ×  10−6 °C−1 respectively as shown in tables 8 and
9. The good agreement between the predicted value and the experimental value confirms the validity of the model.

7. Conclusions

RSM in conjunction with CCRD has been employed for modeling and optimizing the effects of aging parameters
on thermal conductivity and CTE of Al 6082 alloy. The technique has been proved to be economical and efficient,
to get maximum amount of information in a short period of time and with the least number of experiments.
Mathematical models were derived for both thermal conductivity and CTE by using the experimental data and
software package MINITAB 17. The results reveals that aging temperature is most dominant factor for both
thermal conductivity and CTE followed by aging time and solution time. From the developed mathematical
model, the optimal values of aging parameters were found out to achieve the maximum thermal conductivity
and CTE. Predicted values from the model equations were found to be in good agreement with experimental
values for thermal conductivity and CTE. Thermal properties were found to be improved by aging treatment
due to precipitation. Mg2Si precipitates, observed in aluminium matrix were confirmend by XRD and optical
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Mater. Res. Express 4 (2017) 046502 D K Vishwakarma et al

microscopy. Enhanced thermal properties of Al6082 alloy widen its application area for manufacturing the engine
components used at high temperature leads to improved performance and lifetime of component.

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