Mechanical and physical properties of aluminum and its alloys for electrical conductors: A review

This review paper presents a comprehensive analysis of the mechanical, physical, and thermal properties of aluminum and its alloys utilized in electrical conductors. While aluminum is primarily favored for its high electrical conductivity, lightweight nature, and corrosion resistance, its thermal properties also play a crucial role in its performance in power transmission systems. The review covers the historical evolution and classifications of aluminum conductors, including homogeneous and inhomogeneous types, and highlights key aluminum alloys: the 1xxx, 6xxx, and 8xxx series. It explores various methods for enhancing the mechanical properties of these alloys, such as alloying and grain refinement, and discusses the inherent trade-offs with electrical conductivity. Additionally, the impact of heat treatment processes and the incorporation of alloying elements like vanadium, titanium, and boron on both electrical and mechanical performance is examined. Ultimately, the findings aim to guide the selection of optimal aluminum alloy compositions and manufacturing processes, advancing the efficiency and reliability of aluminum-based conductors in the energy sector.