Improving the Complex of Properties of Copper-Clad Aluminum Wire by Using Electromagnetically Cast Al–Fe Alloys

This work is dedicated to the analysis of the influence of the core material on the complex of physical and mechanical properties of copper-clad aluminum wires (CCAW) in hard (hard-drawn) and soft (annealed) states. Low-alloyed aluminium alloys of the Al–Fe system were chosen as research material as an alternative to the conventionally used technically pure aluminium in terms of thermal stability, mechanical strength and ductility. Such alloys, while still retaining low cost and high electrical conductivity, are characterized by the improved relative to technically pure Al mechanical strength and thermal stability. Alloys used in this study were produced by casting into electromagnetic mold to further improve their mechanical properties. Three different alloy compositions Al–0.5 wt % Fe, Al–0.5 wt % Fe–0.3 wt % Cu and Al–1.7 wt % Fe were used. To achieve a hard-drawn state, the copper-clad wire was cold-drawn to a reduction degree of 90%, and the soft state was achieved by annealing at 300 and 325°C for 1 h. To compare CCAW with the core materials produced by electromagnetic casting, samples with similar copper content were produced based on commercial alloy 8176, produced by a traditional combined casting and rolling method. Based on the experimental data obtained and the results of the optimization performed (from the combined tensile strength, ductility and electrical conductivity point of view) using the linear convolution target function, the most suitable alloy of the Al–Fe system as the core material for the CCAW was proposed.