PROCESS FOR FORMING AN ALUMINUM ALLOY WIRE

Abstract

Aluminum alloy wires with improved electrical conductivity and enhanced ultimate tensile strength are disclosed. The aluminum alloys include magnesium, silicon, and copper and are formed without heat treatment in solution. The aluminum alloy wires are useful as conductors for overhead transmission lines. Methods for preparing the aluminum alloy wires are additionally disclosed.

Description

1 / 20 “PROCESS FOR FORMING AN ALUMINUM ALLOY WIRE GOVERNMENT LICENSING RIGHTS

[001] This invention was made with government support under Federal Award No. DE-SC0015232, granted by U.S. Department of Energy. The government has certain rights to the invention. TECHNICAL FIELD

[002] This disclosure generally refers to aluminum alloy wires exhibiting high strength and high electrical conductivity. This disclosure further refers to conductors for overhead transmission lines formed from these aluminum alloy wires. BACKGROUND

[003] Overhead transmission lines are useful for conducting electrical power over long distances and are formed by conductors suspended in the air. The metals used to form the conductors of overhead transmission lines are needed to balance several properties. For example, these metals must exhibit high electrical conductivity to maximize the amplitude of the transmission line and minimize electrical resistance losses and ohmic heating. The metals must also exhibit high strength to allow the conductors to travel long distances between adjacent overhead transmission line towers. Conventionally, these conductors are formed from aluminum alloy.

[004] The Publication of Patent Application EP. No. 3375899 A1 describes an aluminum alloy material that includes: zinc with a mass percentage of 4.5% to 12.0%, magnesium with a mass percentage of 0.7% to 3.0%, copper with a percentage Petition 870230113615, dated 12 / 22 / 2023, page 18 / 43 2 / 20 by mass is less than or equal to 0.6%, titanium whose percentage by mass is from 0.001% to 0.5%, boron whose percentage by mass is from 0.00011% to 0.2%, manganese whose percentage by mass is less than or equal to 0.01%, chromium whose percentage by mass is less than or equal to 0.2%, zirconium whose percentage by mass is less than or equal to 0.2%, silicon whose percentage by mass is less than or equal to 0.3%, iron whose percentage by mass is less than or equal to 0.3%, aluminum and other unavoidable impurities.

[005] U.S. Patent No. 3,418,177 describes a process for preparing aluminum-based alloys in forged form, especially conductive alloys, wherein the alloy contains magnesium and silicon, including the steps of holding at an elevated temperature, hot rolling with a cooling rate during hot rolling greater than 100 °F (37.78°C) per minute and cooling below 250 °F (121.11°C) at a rate greater than 100 °F (37.78°C) per minute with a delay of less than 20 seconds between said cooling and said hot rolling.

[006] U.S. Patent No. 3,842,185 describes an aluminum alloy conductor wire consisting of 98.0 to 99.5% by weight of aluminum, between 0.3 and 1.0 (preferably 0.4 to 0.6)% by weight of iron, between 0.08 and 1.0 (preferably 0.2 to 0.4)% by weight of copper, a maximum of 0.15 (preferably 0.05 to 0.08)% by weight of silicon, and trace amounts of conventional impurities. The conductor wire is especially suitable for use as a conductor in a telecommunications cable or as a component element of an overhead electrical conductor.

[007] US Patent No. 9,564,254 describes a wire of Petition 870230113615, dated 12 / 22 / 2023, p. 19 / 43 3 / 20 aluminum alloy (Al), which is an extra-fine wire having a wire diameter of 0.5 mm or less, contains, by mass %, Mg from 0.03% to 1.5%, Si from 0.02% to 2.0%, at least one element selected from Cu, Fe, Cr, Mn, and Zr totaling 0.1% to 1.0%, the remainder being Al and impurities, and has an electrical conductivity of 40% IACS or more, a tensile strength equal to or greater than 150 MPa, and an elongation of 5% or greater. When producing the extra-fine wire from an Al alloy of a specific composition containing Zr, Mn, and other specific elements, although the extra-fine wire is extra-fine, it has a fine structure with a maximum grain size of 50 μm or less and is superior in elongation. SUMMARY

[008] According to one embodiment, an aluminum alloy wire includes about 0.6% to about 0.9% by weight of magnesium, about 0.5% to about 0.9% by weight of silicon, about 0.05% to about 1.0% by weight of copper, and the remainder is aluminum. The aluminum alloy includes elongated eutectics of Mg2Si.

[009] According to another embodiment, a process for forming an aluminum alloy wire includes forming an aluminum alloy rod and performing a T8 heat treatment or a T9 heat treatment on the aluminum alloy rod to form an aluminum alloy wire in accordance with the American National Standards Institute (ANSI) Alloy and Temper Designation System for aluminum H35.1 and H35.1M (2017). The aluminum alloy includes about 0.6% to about 0.9% by weight of magnesium, about 0.5% to about 0.9% by weight of silicon, about 0.05% to about 1.0% by weight of copper, and the remainder is aluminum. No heat treatment of Petition 870230113615, dated 12 / 22 / 2023, p. 20 / 43 4 / 20 of the solution is implemented. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 represents a cross-sectional view of a conductor according to certain embodiments.

[0011] FIG. 2 represents a cross-sectional view of a conductor according to certain embodiments.

[0012] FIG. 3 represents a cross-sectional view of a conductor according to certain embodiments.

[0013] FIG. 4 represents a cross-sectional view of a conductor according to certain embodiments.

[0014] FIG. 5 represents a graph illustrating the electrical conductivity and ultimate tensile strength of examples of aluminum alloy wires. DETAILED DESCRIPTION

[0015] Conductors for overhead transmission lines are typically manufactured from aluminum or an aluminum alloy, due to the weight, strength, conductivity, and cost benefits of aluminum compared to other metals such as copper. The formation of aluminum alloys exhibiting enhanced electrical conductivity and improved strength has recently been discovered. The increased electrical conductivity and strength make enhanced aluminum alloys particularly suitable for overhead transmission line conductors.

[0016] Generally, the enhanced aluminum alloys described in this document are forged, heat-treatable aluminum alloys, including optimized amounts of magnesium, silicon, and copper. Advantageously, enhanced aluminum alloys can be formed without a solution heat treatment. Petition 870230113615, dated 12 / 22 / 2023, p. 21 / 43 5 / 20

[0017] Specifically, it has been found that improved aluminum alloys, including by weight about 0.6% to about 0.9% magnesium, about 0.5% to about 0.9% silicon, and about 0.05% to about 1.0% copper, can be used to form aluminum alloy wires that exhibit improved electrical conductivity and increased ultimate tensile strength when processed using a suitable heat treatment.

[0018] As can be seen, the improved aluminum alloys may include any amounts of magnesium, silicon, and copper within the ranges described. For example, in certain embodiments, the improved aluminum alloys may include about 0.6% to about 0.8% by weight of magnesium or about 0.65% to about 0.70% of magnesium. In certain embodiments, the improved aluminum alloys may include about 0.50% to about 0.70% by weight of silicon, or about 0.50% to about 0.60% by weight of silicon. In certain embodiments, the improved aluminum alloys described in this document may include, by weight, about 0.05% to about 1% of copper, including amounts between about 0.05% and 1% of copper, such as 0.05% to about 0.5% of copper and about 0.05% to about 0.10% of copper.

[0019] Alloys having higher levels of copper filler, such as about 0.05% or more by weight, have unexpectedly been found to facilitate increased electrical conductivity and mechanical strength of the aluminum alloys described in this document when processed with appropriate heat treatment. It is believed that small additions of copper may modify the precipitation kinetics of the Mg2Si phase, thus allowing desirable improvements. Petition 870230113615, dated 12 / 22 / 2023, page 22 / 43 6 / 20

[0020] As can be seen, these amounts of magnesium, silicon, and copper loading can be advantageous for several reasons. For example, relatively low amounts of magnesium loading (e.g., about 0.6% to about 0.8% by weight) can facilitate the formation and processing of the alloy compared to similar alloys including higher amounts of magnesium. Additionally, the inclusion of the described amounts of magnesium, silicon, and copper can allow the formation of desirable amounts of Mg2Si eutectics and precipitates in the improved aluminum alloy.

[0021] In certain embodiments, the improved aluminum alloys described in this document may additionally include additional elements. For example, in certain embodiments, iron may be included. Iron may be useful to provide improved tensile strength without diminishing the electrical conductivity of the alloy. In such embodiments, iron may be included at about 0.01% to about 0.50% by weight, as high filler levels may impair drawing performance. In certain embodiments, the improved aluminum alloys may include about 0.10% to about 0.35% by weight of iron or about 0.15% to about 0.20% by weight of iron.

[0022] Additionally, or alternatively, inoculants and precipitate refiners may be included to further modify the improved aluminum alloy, influencing the grain and precipitate characteristics in the aluminum matrix. In such embodiments, the inoculants and precipitate refiners may generally be selected from metalloid elements, such as a Petition 870230113615, dated 12 / 22 / 2023, page 23 / 43 7 / 20 or more of tin, bismuth, strontium, indium, lead, and antimony.

[0023] As can be seen, several types of aluminum alloy have been standardized by the Aluminum Association's H35 Accreditation Standards Committee. The standardized aluminum types are defined by their elemental compositions, with the various types generally intended for specific applications and industries. Specific aluminum and magnesium alloys of interest were published by the Aluminum Association in January 2015 in the “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys, including 6000 series aluminum alloys.

[0024] In certain embodiments, the improved aluminum alloys described in this document may be formed by modifying known aluminum alloys of the 6000 series, including, for example, AA6101 and AA6201 aluminum alloys.

[0025] AA6201 aluminum alloys are defined by the Unified Numbering System (“UNS”) standard AA6201 and include, by weight, 0.6% to 0.9% magnesium, 0.50% to 0.90% silicon, 0.50% or less iron, 0.10% or less copper, 0.03% or less manganese, 0.03% or less chromium, 0.10% or less zinc, 0.06% or less boron and 0.03% or less of another element with a total of less than 0.10% of each other element and the remainder aluminum.

[0026] As can be seen, relatively small quantities of other unnoticed elements may also be present in the improved aluminum alloys described in this document due to, for example, processing and refining impurities. Examples of such elements Petition 870230113615, dated 12 / 22 / 2023, p. 24 / 43 8 / 20 may include manganese, chromium, zinc, and boron. In certain embodiments, these elements may be present at levels found in a typical AA6201 aluminum alloy. For example, manganese may be found at approximately 0.002% by weight; chromium may be found at approximately... 0.003% by weight; zinc can be found in approximately 0.002% by weight; and boron can be found at 0.005% by weight, in various forms.

[0027] In certain embodiments, any elements other than aluminum, magnesium, silicon, iron, copper, manganese, chromium, zinc, and boron may be included at about 0.03% by weight or less, with all such elements collectively included at about 0.10% by weight or less.

[0028] It has been advantageously found that wires formed from the aluminum alloys described in that paper exhibit improved electrical conductivity and ultimate tensile strength without the need for solution heat treatment. Prior to the present discovery, it was believed that solution heat treatment would be necessary to improve the electrical conductivity and ultimate tensile strength of a conventional aluminum wire including the current amounts of magnesium and silicon (e.g., about 0.6% to about 0.8% by weight of magnesium and about 0.50% to about 0.70% by weight of silicon).

[0029] As can be seen, a solution heat treatment may be undesirable due to the considerable energy and special heat treatment equipment required by these processes. Instead, improved aluminum alloys can be formed using a T8 heat treatment, a hot spiraling treatment followed by a Petition 870230113615, dated 12 / 22 / 2023, page 25 / 43 9 / 20 subsequent T8 heat treatment or a T9 heat treatment. All heat treatment processes conform to the American National Standards Institute (ANSI) Alloy and Temper Designation System for ANSI H35.1 and H35.1M (2017) aluminum standards.

[0030] As used in this document, a T8 heat treatment generally refers to a process that includes the steps of cold drawing wire from an aluminum rod, and then artificial aging of the drawn wire at a temperature of about 150°C to about 190°C for about 2 to about 24 hours, to improve the final tensile strength and electrical conductivity. Aluminum alloys processed with a T8 heat treatment may exhibit equiaxed crystal grains having aspect ratios of about 5 or less.

[0031] As used in this document, the ratios can be determined as known in the art using, for example, optical microscopy or electron microscopy and measuring the diameter and length of the crystal grains.

[0032] In certain embodiments, a T8 process may be preceded by a hot spiraling process. Generally, in these processes, a hot-rolled aluminum alloy is tempered in a controlled process at a temperature between 170°C and 250°C and then, maintaining this temperature, wound directly and without interruption into a coiled form (e.g., a mandrel). The coiled rod is then allowed to cool in air or in a heated environment, such as a furnace, before the T8 heat treatment (e.g., cold wire drawing followed by artificial aging at 150°C to 190°C) is performed. Petition 870230113615, dated 12 / 22 / 2023, page 26 / 43 10 / 20

[0033] As used in this invention, a “T9 heat treatment” generally refers to a process in which an aluminum rod is artificially aged at a temperature of about 180°C to about 250°C before being drawn into a wire. In certain embodiments, the T9 heat treatment can be carried out for about 16 to about 24 hours. The drawn wire does not age at high temperatures. Aluminum alloys processed with a T9 heat treatment exhibit elongated grains with an aspect ratio of about 10 or greater.

[0034] As used in this invention, a solution heat treatment generally refers to the process performed on an aluminum rod prior to any wire drawing in a T8 process, any artificial aging in a T9 process, or any hot spiraling. In a solution heat treatment process, an aluminum rod is heated and held at a temperature of 500°C to 600°C for 30 minutes to 4 hours and then rapidly cooled to a temperature below 130°C.

[0035] As can be seen, in a solution heat treatment process, the Mg2Si eutectics and other precipitates are dissolved at a desired elevated temperature and remain supersaturated in the aluminum matrix after rapid cooling. Other changes may also occur. Aluminum grain growth is also observed. The absence of elongated Mg2Si eutectics and other precipitates indicates that a solution heat treatment was performed, as these changes in the aluminum matrix will remain even after subsequent processing with a T8 heat treatment, a T9 heat treatment, or a Petition 870230113615, dated 12 / 22 / 2023, page 27 / 43 11 / 20 hot spiralization process.

[0036] In certain embodiments, the improved aluminum alloys described in this document may retain elongated Mg2Si eutectics, as the alloys are processed only with a T8 heat treatment, a T9 heat treatment, and hot spiraling. As used in this document, an elongated or precipitated eutectic may refer to a eutectic or precipitate having an aspect ratio greater than 1. As can be appreciated, these features are normally destroyed by solution heat treatment which would dissolve the Mg2Si eutectics and other precipitates and lower the aspect ratio to about 1.

[0037] Improved aluminum alloys may exhibit improved electrical conductivity and ultimate tensile strength when compared to known AA6201 aluminum alloys. For example, improved aluminum alloys may exhibit an increase in electrical conductivity of approximately 2.5% IACS in certain embodiments. As used in this document, conductivity is measured by comparing the conductivity of the improved aluminum alloy to the conductivity of copper using the International Standard for Annealed Copper (IACS). The IACS value for the conductivity of copper was adopted by the International Electrotechnical Commission (IEC) in 1913 and is defined as 1 / 58 Ω·™2^ at 20°C for 100% IACS conductivity. In certain embodiments, the wires formed from the enhanced aluminum alloys described in this document may exhibit an electrical conductivity of about 54.5% IACS to about 60% IACS. In certain embodiments, these wires may exhibit an electrical conductivity of about 55.0% IACS to about Petition 870230113615, dated 12 / 22 / 2023, p. 28 / 43 12 / 20 59.5% IACS, an electrical conductivity of approximately 55.5% IACS to approximately 58% IACS, or approximately 56.0% to approximately 57.0% IACS.

[0038] In certain embodiments, the wires formed from the improved aluminum alloys described in this document may exhibit an ultimate tensile strength of about 250 MPa or greater, an ultimate tensile strength of about 275 MPa or greater, an ultimate tensile strength of approximately 300 MPa or greater, or an ultimate tensile strength of 330 MPa or greater.

[0039] Wires formed from enhanced aluminum alloys can exhibit a combination of high electrical conductivity and high ultimate tensile strength. For example, in certain embodiments, the wires can exhibit an electrical conductivity of about 54.5% IACS to about 60% IACS and an ultimate tensile strength of about 250 MPa or greater. As can be appreciated, the electrical conductivity and ultimate tensile strength of a wire can be related to improvements in one property, decreasing the other. In certain embodiments, a wire formed from an enhanced aluminum alloy described in this document can be optimized for both electrical conductivity and ultimate tensile strength.

[0040] In certain embodiments, the improved aluminum alloys described in this document may meet or exceed the requirements of ASTM International B398 AA6201-T81 (2015) or AA6201-T83 (2015). In certain embodiments, the improved aluminum alloys described in this document may also, or additionally, meet or exceed the requirements of EN 50183 A12, A13, A14, A15, A16, A17 or A18 standards, as published by the European Committee for Standardization. Petition 870230113615, dated 12 / 22 / 2023, p. 29 / 43 13 / 20 Electrotechnics (hereinafter, CENELEC) in January 2000. As can be seen, meeting or exceeding the requirements of A14, A16, A17 or A18 was previously thought to require solution heat treatment.

[0041] As can be seen, the characteristics of the improved aluminum alloys described in this document can confer multiple advantages when used as a conductor for an overhead transmission line. For example, increased conductivity can allow for increased transmission line ampacity without increasing the size or weight of the conductors. Additionally, increased ultimate tensile strength can allow conductors to run greater distances between support towers and operate at higher temperatures due to reduced deformation.

[0042] As can be seen, the improved aluminum alloys described in this document can be formed into overhead conductors having a variety of configurations, including aluminum conductor steel reinforced (ACSR) cables, aluminum conductor steel backed (ACSS) cables, aluminum conductor composite core (ACCC) cables, and all aluminum alloy conductor (AAAC) cables. ACSR, ACSS, ACCC, and AAAC cables can be used as overhead cables for overhead distribution and transmission lines.

[0043] ACSR cables are high-strength filament conductors and include outer conductor filaments and central support filaments. The outer conductor wires may be formed from the improved aluminum alloys described in this document. The central support wires may be made of steel and may have the necessary strength to support Petition 870230113615, dated 12 / 22 / 2023, pages 30 / 43 14 / 20 the outer conductive filaments are more ductile. ACSR cables can have high tensile strength. ACSS cables are concentric layer filament cables and include a central steel core around which one or more layers of the enhanced aluminum alloy described in this document is / are filamented.

[0044] ACCC cables, in contrast, are reinforced by a central core formed from one or more carbon, fiberglass, or polymer materials. A composite core can offer a variety of advantages over a conventional cable reinforced entirely with aluminum or steel, as the combination of the high tensile strength and low thermal deformation of the composite core allows for longer spans. ACCC cables can enable the construction of new lines with fewer support structures.

[0045] AAAC cables can be formed with the improved aluminum alloys described in this document. AAAC cables can have improved corrosion resistance due to the fact that they are largely, or completely, aluminum.

[0046] FIGS. 1, 2, 3 and 4 illustrate cross-sections of various bare overhead conductors suitable for overhead transmission lines according to certain embodiments.

[0047] As represented in FIG. 1, certain bare overhead conductors 100 may generally include a core 110 made of one or more wire(s), a plurality of round cross-section conductor wires 120 located around the core 110, and an optional sheath 130. The sheath 130 may be any protective coating as known in the art. The core 110 may be of steel, composite carbon fiber, steel invar, carbon fiber Petition 870230113615, dated 12 / 22 / 2023, pp. 31 / 43 15 / 20 composite or any other material that can provide strength to the conductor. 120 conductor wires may be formed from the improved aluminum alloys described in this document.

[0048] As represented in FIG. 2, certain bare overhead conductors 200 may generally include round conductor wires 210 and an optional sheathing layer 220. The conductor wires 210 may be formed from the improved aluminum alloys described in this document.

[0049] As seen in FIG 3, certain bare overhead conductors 300 may generally include a core 310 of one or more wire(s), a plurality of trapezoidal conductor wires 320 around a core 310, and an optional sheath 330. The sheath 330 may be sheathed onto conductor wires 320 or may be sheathed only on the exposed outer portion of the cable 300. The core 310 may be of steel, steel invar, composite carbon fiber, or any other material that provides strength to the conductor. The conductor wires 320 may be formed from the improved aluminum alloys described in this document.

[0050] As represented in FIG. 4, certain bare overhead conductors 400 may generally include trapezoidal-shaped conductor wires 410 and an optional sheathing layer 420. The conductor wires 410 may be formed from the improved aluminum alloys described in this document.

[0051] In certain embodiments, the improved aluminum alloys described in this document may alternatively be used for transmission line accessories, including transformers, insulators, blind end / termination products, splices / joints, products, suspension products. Petition 870230113615, dated 12 / 22 / 2023, pages 32 / 43 16 / 20 and support, motion control / vibration dampers, gripping products, wildlife protection and obstruction products, fitting repair parts for conductors and compression fittings, substation products, clamps and other transmission and distribution fittings. Alternatively, improved aluminum alloys may also be used for any other known application for which a 6000 series aluminum alloy is useful.

[0052] In certain embodiments, the elemental composition of the aluminum alloys described in this document can be formed through a casting process. For example, substantially pure aluminum can be melted at a temperature of about 537°C to 704°C (1000°F to about 1300°F), and then additional elements such as magnesium, silicon, and copper can be added according to their desired weight percentage. In certain embodiments, certain elements can optionally be added using a grain refiner to further control the microcrystalline structure. Once all elements are present according to the desired weight percentage, the molten aluminum mixture can be cast. Alternatively, an existing aluminum alloy can be melted and additional elements can be incorporated. In certain embodiments, a casting process can be used as known in the art.

[0053] As can be observed, many variations are known in the casting process of an aluminum alloy. For example, several stirring steps can be performed on a molten aluminum mixture to improve Petition 870230113615, dated 12 / 22 / 2023, pages 33 / 43 17 / 20 homogeneity. Additionally, or alternatively, a molten aluminum mixture can be allowed to settle for a period of time to allow unwanted inclusion particles to be deposited as sediment and removed. In a certain embodiment, a molten aluminum mixture can also be refined to remove impurities using, for example, alloying constituents and precise temperature control to precipitate unwanted impurities from the molten mixture.

[0054] In certain embodiments, once cast, an improved aluminum alloy can be formed by hot rolling to form a rod and then using an appropriate heat treatment on the rod. For example, the rod can be processed using a T8 heat treatment, hot rolling and T8 heat treatment, or a T9 heat treatment, as described earlier in this document.

[0055] In certain embodiments, the entire process may be continuous. For example, the aluminum alloy described in this document may be continuously cast, continuously hot-rolled on a rod, and thus continuously processed using one or more of the hot rolling, T8 heat treatment, and T9 heat treatment processes. Alternatively, one or more step(s) may be intermittent in other embodiments. EXAMPLES

[0056] Table 1 shows several example wires of aluminum alloys that were formed to evaluate the effect of modifying the compositional formula of an aluminum alloy and the use of different heat treatments. Examples 1 and 5 to 12 are comparative wires of AA6201 aluminum alloy. Petition 870230113615, dated 12 / 22 / 2023, pp. 34 / 43 18 / 20 containing 0.002% by weight of copper. Examples 1A and 1B were prepared with a T8 heat treatment. Examples 5 to 12 represent standardized wires prepared according to CENELEC EN 50183 (2000) (examples 5 to 10) or ASTM B398 (2015) (examples 11 and 12). As can be seen, the CENELEC EN 50183 A14, A15 and A16 aluminum wires (examples 5, 6 and 9) require a solution heat treatment (S).

[0057] Examples 2 to 4 are wires formed from an aluminum alloy including 0.10% by weight of copper. Examples 2A to 2E were prepared using a combination of hot spiraling (HC) and a T8 heat treatment with varying temperatures and aging times (indicated in Table 1). Examples 3A and 3B were prepared using a T8 heat treatment, but without a hot spiraling process, with the temperatures and aging times indicated in Table 1. Examples 4A and 4B were prepared using a T9 heat treatment with the temperatures and aging times indicated in Table 1.

[0058] Table 1 further illustrates the electrical conductivity and ultimate tensile strength of each of examples 1 to 12. TABLE 1 Example Composition Heat Treatment Temp. of Aging (°C) Aging Time (h) Electrical Conductivity (% IACS) Resistance (MPa) 1A AlMg0.65Si0.5 0Fe0.18CuQ.0Q2 T8 165 2 52.5 330 1B AlMg0.65Si0.5 0Fe0.18CuQ.0Q2 T8 175 8 57.5 255 2A AlMg0.64Si0.5 8Fe0.17Cu0.10 HC+T8 165 6 55.8 330 2B AlMg0.64Si0.5 8Fe0.10.17Cu+T80.80. 24 59.0 255 2C AlMg0.64Si0.5 8Fe0.17Cu0.10 HC+T8 165 16 54.8 342 2D AlMg0.64Si0.5 8Fe0.17Cu0.10 HC+T8 175 157.23 13 E AlMg0.64Si0.5 8Fe0.17Cu0.10 HC+T8 175 16 58.5 300 3A AlMg0.64Si0.5 8Fe0.17Cu0.10 T8 155 14 54.9 330 3B AlMg0.64Si0.5 8Fe0.17Cu0.10 T8 185 24 58.5 255 4A AlMg0.64Si0.5 8Fe0.17Cu0.10 T9 200 16 56.9 330 Petition 870230113615, of 22 / 12 / 2023, p. 35 / 43 19 / 20 4B AlMg0.64Si0.5 8FeQ,17CuQ,1Q T9 215 24 59.2 255 5 A14 S+T8 — — 52.9 342 6 A16 S+T8 — — 55.6 314 7 A12 T8 — — 32.5 — A135 — A18 295 9 A15 S+T9 — — 55.25 295 10 A17 / A18 T8 — — 57.5 300 11 6201-T81 T8 — — 52.5 330 12 6201-T83 T8 — — 53 295

[0059] As represented in Table 1, inventive examples 2 to 4, representing wires formed from aluminum alloys, including, by weight, 0.64% magnesium, 0.50% silicon, 0.18% iron and 0.10% copper, exhibited desirable electrical conductivity and ultimate tensile strength when processed with a T8 or T9 heat treatment process, even without the use of a solution heat treatment.

[0060] FIG. 5 represents a graph comparing examples of the invention 2A to 2E to comparative examples 5 to 12. As represented in FIG. 5, examples of the invention 2A to 2E outperformed the comparative examples, demonstrating high levels of electrical conductivity and ultimate tensile strength.

[0061] It should be understood that all maximum numerical limitations provided throughout this descriptive report include all lower numerical limitations, as if those lower numerical limitations were expressly written in this document. Every minimum numerical limitation given throughout this descriptive report will include every upper numerical limitation, as if those upper numerical limitations were expressly written in this document. Every numerical range provided through this descriptive report will include every narrower numerical range that falls within a numerical range. Petition 870230113615, dated 12 / 22 / 2023, pages 36 / 43 20 / 20 wider, as if these narrower numerical ranges were all expressly written in that document.

[0062] Every document cited in this document, including any related or cross-referenced patent or application, is incorporated into this document by reference in its entirety, unless expressly excluded or otherwise limited. Citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed in this document or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any invention. Furthermore, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition ascribed to that term in this document shall prevail.

[0063] The preceding description of embodiments and examples has been presented for descriptive purposes. It is not intended to be exhaustive or limiting to the forms described. Numerous modifications are possible in light of the above teachings. Some of these modifications have been discussed, and others will be understood by those skilled in the art. The embodiments have been chosen and described for illustration to those skilled in the art. Instead, it is intended that the scope be defined by the claims attached to various embodiments. The scope is not, of course, limited to the examples or embodiments set forth in this invention, but may be employed in any number of applications and articles equivalent to those described in this document. Petition 870230113615, dated 12 / 22 / 2023, pages 37 / 43

Claims

1 / 4 CLAIMS 1. Process for forming an aluminum alloy wire, the process characterized in that it comprises: forming an aluminum alloy rod from an aluminum alloy, the aluminum alloy comprising: 0.6% to 0.9% by weight of magnesium; 0.5% to 0.9% by weight of silicon; 0.05% to 1.0% by weight of copper; and the remainder being aluminum; and performing a T8 heat treatment or a T9 heat treatment on the aluminum alloy rod to form an aluminum alloy wire, in accordance with the American National Standards Institute (ANSI) Alloy and Temper Designation System for aluminum H35.1 and H35.1M (2017); wherein the T8 heat treatment comprises cold drawing of aluminum alloy rod to form an unaged wire; and artificially aging the unaged wire at a temperature of 150°C to 190°C for 2 to 24 hours; wherein the T9 heat treatment comprises artificially aging the aluminum alloy rod at a temperature of 180°C to 250°C to form a heat-treated aluminum alloy rod; and drawing of the heat-treated aluminum alloy rod to form the aluminum alloy wire; and wherein no solution heat treatment is performed, wherein the solution heat treatments are solution heat treatment processes performed on the aluminum alloy rod prior to cold drawing of the T8 heat treatment, the artificial aging of the treatment Petition 870260029767, dated 30 / 03 / 2026, p. 18 / 27 2 / 4 thermal T9, or hot spiral.

2. Process according to claim 1, characterized in that performing a T8 heat treatment or a T9 heat treatment on the aluminum alloy rod to form an aluminum alloy wire comprises performing the T8 heat treatment.

3. Process according to claim 2, characterized in that it further comprises the step of hot spiraling of the aluminum alloy rod at a temperature of 170°C to 250°C.

4. Process according to claim 1, characterized in that performing a T8 heat treatment or a T9 heat treatment on the aluminum alloy rod to form an aluminum alloy wire comprises performing the T9 heat treatment.

5. Process according to claim 1, characterized in that the formation of the aluminum alloy rod comprises hot casting of the aluminum alloy rod from a molten mixture.

6. Process according to claim 1, characterized by being continuous.

7. Process according to claim 1, characterized in that the aluminum alloy wire comprises elongated Mg2Si eutectics.

8. Process according to claim 1, characterized in that the aluminum alloy comprises 0.05% to 0.1% by weight of copper.

9. Process, according to claim 1, characterized in that the aluminum alloy further comprises 0.01% to 0.50% by weight of iron. Petition 870260029767, dated 03 / 30 / 2026, pp. 19 / 27 3 / 4 10. Process according to claim 1, characterized in that forming the aluminum alloy rod comprises modifying the aluminum alloy, wherein the aluminum alloy may include 6000 series aluminum alloys.

11. Process according to claim 10, characterized in that the 6000 series aluminum alloys are AA6101 and AA6201 aluminum alloys.

12. Process for forming an aluminum alloy wire, the process characterized in that it comprises: forming an aluminum alloy rod from an aluminum alloy, the aluminum alloy comprising: 0.6% to 0.9% by weight of magnesium; 0.5% to 0.9% by weight of silicon; 0.05% to 1.0% by weight of copper; and the remainder being aluminum; and performing a T8 heat treatment or a T9 heat treatment on the aluminum alloy rod to form an aluminum alloy wire, according to the American National Standards Institute (ANSI) Alloy and Temper Designation System for aluminum H35.1 and H35.1M (2017); wherein heat treatment T8 comprises cold drawing of aluminum alloy rod to form an unaged wire; and artificially aging the unaged wire at a temperature of 150°C to 190°C for 2 to 24 hours; wherein heat treatment T9 comprises artificially aging the aluminum alloy rod at a temperature of 180°C to 250°C to form a heat-treated aluminum alloy rod; and drawing of the alloy rod of Petition 870260029767, dated 03 / 30 / 2026, p.20 / 27 4 / 4 aluminum heat-treated to form aluminum alloy wire; wherein the aluminum alloy wire comprises elongated Mg2Si eutectics; and wherein no solution heat treatment is performed, wherein solution heat treatments are solution heat treatment processes performed on the aluminum alloy rod prior to cold wire drawing of heat treatment T8, artificial aging of heat treatment T9, or hot spiraling, so that the elongated Mg2Si eutectics can be retained in the aluminum alloy wire.

13. Process according to claim 12, characterized in that performing a T8 heat treatment or a T9 heat treatment on the aluminum alloy rod to form an aluminum alloy wire comprises performing a T8 heat treatment.

14. Process according to claim 13, characterized in that the elongated Mg2Si eutectics have an aspect ratio greater than 1 to 5.

15. Process according to claim 12, characterized in that performing a T8 heat treatment or a T9 heat treatment on the aluminum alloy rod to form an aluminum alloy wire comprises performing a T9 heat treatment.

16. Process according to claim 15, characterized in that the elongated Mg2Si eutectics have an aspect ratio of 10 or greater. Petition 870260029767, dated 03 / 30 / 2026, pp. 21 / 27

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