| Summary: | In this study, Al<sub>2</sub>O<sub>3</sub>–siloxane composite thermal pads were fabricated using a tape–casting technique, and the thermal conductivity effect of the Al<sub>2</sub>O<sub>3</sub> nanoparticle powder synthesized using a flame fusion process on siloxane composite thermal pads was investigated. Furthermore, various case studies were implemented, wherein the synthesized Al<sub>2</sub>O<sub>3</sub> nanoparticle powder was subjected to different surface treatments, including dehydration, decarbonization, and silylation, to obtain Al<sub>2</sub>O<sub>3</sub>–siloxane composite thermal pads with high thermal conductivity. The experimental results confirmed that the thermal conductivity of the Al<sub>2</sub>O<sub>3</sub>–siloxane composite pads improved when fabricated using surface–treated Al<sub>2</sub>O<sub>3</sub> nanoparticle powder synthesized with an optimally spheroidized crystal structure compared to that produced using non–treated Al<sub>2</sub>O<sub>3</sub> nanoparticle powder. Therefore, this study provides guidelines for fabricating Al<sub>2</sub>O<sub>3</sub>–siloxane composite thermal pads with high thermal conductivity in the field of thermal interface materials.
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