Aluminum alloys for electrical engineering: a review

1. Overview:

• Title: Aluminum alloys for electrical engineering: a review
• Author: Frank Czerwinski
• Year of Publication: 2024
• Journal/Conference: J Mater Sci
• Keywords: Aluminum alloys, electrical conductivity, strength, lightweighting, electric vehicles, transmission lines, processing techniques

2. Research Background:

High-performance conductors are essential for economically and environmentally sustainable electricity transfer in modern infrastructure, manufacturing, and transportation, including electric vehicles. While copper has been the traditional conductor of choice, aluminum offers significant advantages in terms of cost and weight reduction for electricity transmission and distribution. Over 14% of global aluminum consumption (over 4.2 to 5 million metric tons out of 64.2 million tons in 2021) is dedicated to electricity transmission and distribution.

Over the next 10 years, more than 320,000 km of transmission lines will require replacement in North America alone. Upgrading existing conductors and increasing load limits enhances grid resilience, transmission capacity, and cost-effective clean energy integration. Aluminum is two to three times less expensive and significantly more abundant than copper.

While possessing 61% of copper's conductivity, it weighs only 30%, resulting in conductors approximately 50% lighter than copper equivalents. For automotive wiring, aluminum can reduce wiring weight from 25 kg to 10 kg per vehicle. This review comprehensively examines aluminum alloys for electrical engineering applications.

3. Research Objectives and Questions:

• Research Objective: To assess the metallurgical characteristics of aluminum alloys used in electrical engineering, current commercial solutions, future development strategies, and new opportunities for aluminum conductors in various applications (power transmission and distribution, electric vehicles, etc.).
• Key Research Questions: What strategies can overcome the strength-conductivity trade-off in aluminum conductor materials, and what are the future development directions for aluminum alloys in electrical engineering?
• Research Hypothesis: Novel alloy designs, advanced processing techniques, and composite material designs can overcome the strength-conductivity trade-off and improve the performance of aluminum conductors.

4. Research Methodology:

• Research Design: Literature review
• Data Collection Methods: Comprehensive literature search and analysis of relevant academic publications and industry reports.
• Analysis Methods: Analytical review of the metallurgical characteristics of aluminum alloys, current commercial solutions, novel development strategies, and a variety of applications.
• Research Subjects and Scope: Aluminum alloys and related technologies for electrical engineering applications.

5. Main Research Results:

• Key Findings: The inherent advantages and disadvantages of aluminum for electrical engineering are highlighted. Strategies to overcome the strength-conductivity trade-off are discussed. Various alloying elements (transition metals, rare earths), processing techniques (ultra-fast crystallization, severe plastic deformation, complex thermomechanical treatments), and composite materials (cladding, particulate reinforcement) are evaluated. Applications across transmission and distribution, electric vehicles, and other sectors are analyzed.
• Quantitative/Qualitative Analysis Results: Comparison of the electrical conductivity, strength, thermal stability, and other properties of various aluminum alloys. Analysis of the effects of different alloying elements and processing techniques on the strength and conductivity trade-off.
• Data Interpretation: Analysis of the changes in electrical conductivity and strength as a function of alloying element type and content. The influence of microstructure control (grain size, texture, grain boundary engineering) on conductivity and strength is investigated. The effectiveness of composite materials (cladding, particle reinforcement) is analyzed.
• Figure List and Description: The paper includes numerous figures and graphs illustrating the microstructure, electrical conductivity, strength, thermal stability, and other properties of various aluminum alloys. Examples include Figures illustrating the conductivity-thermal conductivity relationship in various metals, the strength-conductivity relationship in different conductors, applications of aluminum conductors, factors affecting the performance of aluminum conductors, the strength-conductivity trade-off, the role of grain boundaries in electron scattering, and various alloying and processing strategies. Figures also depict microstructures of various aluminum alloys and composites.

6. Conclusion and Discussion:

This review provides a comprehensive overview of aluminum alloys for electrical engineering, analyzing their properties and the strategies used to overcome the strength-conductivity trade-off. The results suggest that novel alloy designs, processing techniques, and composite material approaches can improve the performance of aluminum conductors. This research offers significant academic and practical implications for increasing the use of aluminum conductors in power transmission and distribution and electric vehicles. However, further research is needed to experimentally verify some findings, and to fully explore the advantages and disadvantages of specific alloys and processing techniques.

7. Future Research:

• Future Research Directions: Further experimental research is required to investigate the strength-conductivity trade-off in different aluminum alloy systems. More research is needed on novel alloy designs, advanced processing techniques, and composite material designs. Studies focusing on applications in emerging fields such as electric vehicles are particularly important.
• Areas Requiring Further Exploration: Improvements in high-temperature thermal stability, corrosion resistance, connection and termination technologies, and long-term reliability in real-world applications require further investigation.

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Copyright:

This abstract is based on the paper "Aluminum alloys for electrical engineering: a review" by Frank Czerwinski.
Paper Source: https://doi.org/10.1007/s10853-024-09890-0
This abstract is a summary and should not be used for commercial purposes without permission.
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