Abstract: This disclosure relates to a method and apparatus for manufacturing an aluminum alloy electrical conductor which promote the formation of a wire having a fine, stable subgrain structure of small cell size in the aluminum matrix and a fine dispersion of stable, insoluble intermetallic phase particles. The subgrain structure is improved by closely controlling the thermomechanical processing, particularly the casting rate, deformation parameters and annealing characteristics. After casting, the cast product is substantially immediately hot-formed in a rolling mill wherein the first deformation is more than 30% such that a substantially well defined subgrain structure will be formed in the aluminum matrix, thereby maximizing a refinement of the subgrain structure by permitting breaking-up thereof in each of the subsequent deformations in the rolling mill. After cold-working, without preliminary or intermediate anneals, the product is finally annealed at a temperature not exceeding approximately 700.degree. F.

Abstract: Improved aluminum alloy electrical conductors and method for making same are disclosed. The alloy contains from about 0.55 to about 0.65 weight percent nickel, the remainder aluminum with associated trace elements including no more than 0.15 weight percent iron, no more than 0.001 weight percent magnesium and no more than 0.05 weight percent copper.

Abstract: An aluminum alloy electrical conductor having an electrical conductivity of at least fifty-seven percent (57%) based on the International Annealed Copper Standard and unexpected properties of increased bendability, creep resistance, fatigue resistance and thermal stability at a minimum standard elongation, when compared to conventional aluminum alloy conductors of the same tensile strength is described. The aluminum alloy conductors are produced by the addition of from about 0.10 weight percent to about 1.00 weight percent copper and up to about 0.10 weight percent iron to an alloy mass containing from about 98.70 weight percent to about 99.90 weight percent aluminum, and trace quantities of conventional impurities normally found within a commercial aluminum alloy.

Abstract: This invention relates to a method for continuously casting an aluminum-copper and an aluminum-copper-iron alloy having an acceptable electrical conductivity and improved elongation, bendability and tensile strength wherein the method generally comprises the steps of pouring molten aluminum alloy into the groove of a continuous casting mold, cooling the molten aluminum in the casting groove, hot forming the cast bar to form a rod and continuously coiling the rod at a temperature of from about 250.degree. F. to 700.degree. F.

Abstract: This disclosure relates to a high tensile strength aluminum alloy electrical conductor that is manufactured by alloying at least one alloying element with molten aluminum in sufficient proportion to yield intermetallic precipitates during subsequent solidification and thermomechanical processing. The conductor is in the form of a hard-drawn wire which is annealed at a temperature within the range corresponding to the onset of recovery such that there will be produced secondary intermetallic precipitates corresponding to the primary precipitates which come out of solution during casting, whereby both the primary and secondary precipitates act to pin dislocation sites between adjacent subgrain boundaries in the aluminum matrix thereby increasing the ultimate tensile strength and yield strength of the conductor.

Abstract: This disclosure relates to an aluminum alloy electrical conductor which contains from about 0.20% to about 1.60% by weight nickel, from about 0.30% to about 1.30% iron, optionally up to 2.00% of additional specified alloying elements, and the remainder aluminum with associated trace elements. The conductors are processed in a continuous operation which includes continuous casting, hot-rolling in the as-cast condition to form continuous rod, cold-working of the rod by drawing it through a series of wire-drawing dies, without preliminary or intermediate anneals, and thereafter annealing the wire to achieve a minimum electrical conductivity of 58% IACS, an ultimate tensile strength of at least 12,000 psi, a yield strength of at least 8,000 psi and an elongation of at least 12% when measured as a No. 10 AWG wire. The additional alloying elements are precisely controlled in order to facilitate the continuous processing of the cast bar without splitting and cracking of the subsequently rolled and cold-drawn rod.

Abstract: Aluminum alloy electrical conductors are produced from aluminum base alloys containing from about 0.55 percent to about 0.95 percent by weight nickel, optionally up to about 2.00 percent of additional alloying elements, and from about 97.45 percent to about 99.45 percent by weight aluminum. The alloy conductors have an electrical conductivity of at least 57 percent, based on the International Annealed Copper Standard (IACS), and improved properties of increased thermal stability, tensile strength, percent ultimate elongation, ductility, fatigue resistance and yield strength as compared to conventional aluminum alloys of similar electrical properties.

Abstract: An aluminum alloy wire having an electrical conductivity of at least sixty-one percent (61%) based on the International Annealed Copper Standard and unexpected properties of increased ultimate elongation, bendability and fatigue resistance when compared to conventional aluminum alloy wire of the same tensile strength. The aluminum alloy wire contains substantially evenly distributed iron aluminate inclusions in a concentration produced by the addition of more than about 0.30 weight percent iron to an alloy mass containing less than about 99.70 weight percent aluminum, no more than 0.15 weight percent silicon, and trace quantities of conventional impurities normally found within a commercial aluminum alloy. The substantially evenly distributed iron aluminate inclusions are obtained by continuously casting an alloy consisting essentially of less than about 99.70 weight percent aluminum, more than 0.30 weight percent iron, no more than 0.