Heat-resistant wire formed by researchers in Russia with a new aluminum (Al) alloy could replace more expensive and heavier copper conductors in aircraft and high-speed rail transport. The wire features an optimal combination of strength, thermal stability and electrical conductivity.

The high-strength wire is made from an Al alloy initially cast as a long billet, about 10 mm in diameter, in an electromagnetic crystallizer. Innovative annealing and electromagnetic casting techniques were applied to incorporate thermally stable nanoparticles that contain copper, manganese and zirconium into the material.

Wires produced with the heat-resistant alloy could find use in aircraft and rail applications. Source: National University of Science and Technology

Researchers from National University of Science and Technology and Siberian Federal University formed thin wire from the alloy, which proved thermally stable at temperatures of up to 400° C, a marked improvement relative to existing Al alloys that typically only remain functional up to temperatures of 300° C.

A patent is being sought for the wire production method detailed in Materials Letters.