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Aluminum-Nickel Alloys

Aluminum-Nickel Alloys for high Strength-High Conductivity Applications

Introduction

Aluminum-Nickel alloys ranging from 0.06 pct to 6.1 pct (by wt) Ni has been developed for high strength-high conductivity applications. These alloys were produced by solidification in a permanent mold followed by homogenization, hot extrusion or hot rolling and cold drawing to wire form. This sequence of fabrication a) led to the production of fine fibrous dispersoids of NiAl₃ as part of the Al-Nial₃ eutectic during the initial casting operation, b) permitted the retention of fine fibrous dispersiods of NiAl₃ produced during casting without any significant coarsening during processing and c) led to uniform dispersion and general alignment of these fibrous dispersoids aloing a given direction in the product without any measurable fiber-matrix separation, extensive fiber-fragmentation as aluminum and when processed by the above sequence, possess very attractive combination of high strength-high electrical conductivity, Tensile strengths range from 173N/mm². Using simple composite rules, the estimated strength and the conductivity of NiAl₃ fibers were found to be 1380N/mm² and 18 pct IACS respectively, in these wires.

The use of aluminum alloys as stranded conductors for transmission and distribution of electrical energy has increased rapidly. Aluminum of controlled purity (EC Grade has a minimum conductivity of about 61.0 pct IACS. EC grade aluminum has only moderate mechanical strength even in hard drawn condition, necessitating a close spacing of poles and pylons to limit the catenary self support. EC grade aluminum has a minimum of 99.45 pct aluminum with controlled impurities.

Alloys

Pure aluminum (99.9 pct) and Al-20 Ni master alloy were used to prepare the following alloys: Al-0.6 pct Ni, Al-1.1 pct Ni, Al-3.2 pct Ni, Al-5.0 pct Ni, Al-6.1 pct Ni.

Chemical composition of the alloys

Chemical Composition of Aluminum-Nickel* Conductor Wires
Nominal Composition	Actual Composition, Wt Pct
Nominal Composition	Ni	Fe	Si	Ti	Cr	Zr	V
Al	0.0	0.01	0.01	0.01	0.01	0.01	0.01
Al-0.6 Ni	0.6	0.02	0.03	0.01	0.01	0.01	0.01
Al-1.1 Ni	1.12	0,05	0.03	0.01	0.03	0.01	0.01
Al-3.2 Ni	3.20	0,01	0.03	0.01	0.01	0.01	0.01
Al-5.0 Ni	4.98	0,03	0.03	0.01	0.01	0.01	0.01
Al-6.1 Ni	6.1	0.01	0.01	0.01	0.01	0.01	0.01

Notes: Cu, Mg, Mn and B in all alloys were individually <0.005 pct.

Ti, Cr, V in all alloys were individually <0.01 pct.

*The alloys made from commercially pure aluminum and Al-20 pct Ni master alloy of following compositions;

CONCLUSIONS

1)Aluminum-Nickel alloys ranging from 0 to 6.1 pct Ni (by weight), solidified in 41 mmm diam permanent molds, can be processed to 1.78 mm diam wire using either hot extrusion, or hot rolling, followed by cold drawing.

2)The processing sequence, developed in this investigation, to reduce Al-Ni alloys from cast form to wire form led to general alignment of fibrous dispersoids of NiAl₃ without fiber-fragmentation or coarsening or fiber-matrix separation.

3)These alloys in wire form possess excellent combination of high strength and high electrical conductivity. Tensile strength range from 173N/mm² (at 0.6 pct Ni) to 246 N/mm² (at 6.1 pct Ni) in combination with corresponding conductivity values between 62 pct IACS and 55.5 pct IACS.

4)The processed alloys also possess excellent yield strength; for instance—Al-6.1 pct Ni alloy wire has a 0.2 pct offset strength of 213.5N/mm².

5)Strength and conductivity of the fine fibrous dispersoids of NiAl₃ in these wires, estimated using simple composite rules, are equivalent to 1380 N/mm² and 18 pct IACS respectively.

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