Claims:
1. An aluminum based alloy composition for manufacturing an aluminum alloy conductor wire rod, the aluminum based alloy composition comprising:

99.25 to 99.50 % aluminum by weight;
0.01 to 0.002 % boron by weight;
0.010 to 0.050 % copper by weight;
0.200 to 0.350 % zirconium by weight;
0.050 to 0.070 % silicon by weight; and
0.150 to 0.190 % iron by weight and wherein the aluminum alloy conductor wire rod has a pre-defined ultimate tensile strength in a range of 150 MPa to 200MPa.

2. The aluminum based alloy composition as recited in claim 1, further comprising upto 0.005 % magnesium by weight.

3. The aluminum based alloy composition as recited in claim 1, further comprising upto 0.001 % manganese by weight.

4. The aluminum based alloy composition as recited in claim 1, further comprising upto 0.002 % chromium by weight.

5. The aluminum based alloy composition as recited in claim 1, further comprising upto 0.014 % nickel by weight.

6. The aluminum based alloy composition as recited in claim 1, further comprising up to 0.001 % zinc by weight.

7. The aluminum based alloy composition as recited in claim 1, further comprising up to 0.001 % titanium by weight.

8. The aluminum based alloy composition as recited in claim 1, further comprising up to 0.011 % vanadium by weight.

9. The aluminum based alloy composition as recited in claim 1, further comprising up to 0.008 % tin by weight.

10. The aluminum based alloy composition as recited in claim 1, further comprising up to 0.002 % lead by weight.

11. The aluminum based alloy composition as recited in claim 1, wherein the aluminum alloy conductor wire rod has a pre-defined conductivity in the range of 59.5 % to 60.5 % IACS and wherein the aluminum alloy conductor wire rod has a pre-defined heat resistance in the range of 90 % to 94 %.
, Description:TECHNICALFIELD
[0001] The present disclosure relates to a field of overhead transmission line conductor technology and, in particular, relates to an aluminum based Al3Zr alloy composition for use in manufacturing electrical overhead conductors.

BACKGROUND
[0002] Aluminum alloys play an important role in the field of electrical power transmission lines. These aluminum alloys are widely used to manufacture overhead electric power conductors. These conventional overhead electric power conductors have limited continuous operating temperature range and possess low thermal resistance when operating above 100 °C. There have been attempts to produce aluminum alloys which are suitable for continuous operating temperature of 210 °C. These efficient aluminum based alloy overhead electric conductors possess high current carrying capacity and high thermal resistance required for continuous working at high temperature of about 210 °C.

[0003] Traditionally, EC grade aluminum 1370 is utilized to manufacture the overhead electric power conductors. Over the years, aluminum alloys such as (Mg-Si) 6101 and 6201 are also used to manufacture overhead conductors. These aluminum alloys bear multiple metal elements. The presence or absence of these metal elements in a specified amount characterizes multiple properties of the aluminum alloys. Two of such properties are thermal resistance and high operating temperature. For example, the low thermal resistance of aluminum alloys such as (Mg-Si) 6101, 6201& 1370 grade is due to low recrystallization temperature. In addition, the power transmission capacity of these aluminum alloys is limited due to their incapability to operate at high temperature. The above challenges can be overcome by using zirconium as an element in manufacturing the aluminum alloy. The addition of zirconium to the aluminum increases the recrystallization temperature of the aluminum alloy and hence improves the thermal and mechanical performance of the overhead conductors.

[0004] The prior arts have tried to come up with suitable aluminum alloy composition to address these problems. In one of the prior arts, a composition of an Al-Fe-Tl-RE aluminum alloy is disclosed. The Al-Fe-Tl-RE aluminum alloy includes 0.0l~1.6wt% of Fe; 0 001~0 3wt% of Cu; 0 001~0 3wt% of Mg; 0.001~0 3wt% of Co; 0 001~0 2wt% of Be; 0 001~0 3wt% of Ca; 0 001~0 2wt% of Zn; 0 001~0 3wt and 0 001~0 3wt% of Zr. In addition, the Al-Fe-Tl-RE aluminum alloy includes 0 002~0 25wt% of Li;0 001 ~0 2wt% of Na; 0 002~0 25wt% of K; 0.001~0 2wt% of Ti; 0 001~0 15wt% of V; 0 001~0 12wt% of Cr; 0 001~0 12wt% of Mn and 0 001~0 2wt% of Ga. Moreover, the Al-Fe-Tl-RE aluminum alloy includes 0 003~0 2wt% of Ge; 0 001 ~0 2wt% of Rb; 0 001~0 15wt% of Nb; 0 001~0 2wt% of Mo; 0 001~0 25wt% of Tc; 0 001~0 15wt% of Ru; 0 002~0 lwt% of Rh; 0 001~0 12wt% of Pd and 0 001~0 lwt% of Ag. Further, the Al-Fe-Tl-RE aluminum alloy includes 0 002~0 13wt% of Cd; 0 003~0 18wt% of In; 0 001~0 08wt% of Sn; 0 001~0.3wt% of Sb; 0 001~0 2wt% of Cs; 001~0 08wt% of Ba;.0 001~0 22wt% of Hf and 0 002~0 16wt% of Ta. In addition, the Al-Fe-Tl-RE aluminum alloy includes 0 002~0 18wt% of Re; 0 001 ~0 08wt% of W; 0 002~0 08wt% of Os; 0 001~0 15wt% of Ir; 0 001~0 05wt% of Au;0 08wt% of Pt; 0 002~0 15wt% of Tl and 0 01~3 0wt% of RE. Furthermore, the Al-Fe-Tl-RE aluminum alloy includes greater than zero and less than or equal to 0.2wt% of Si; greater than zero and less than or equal to 0.8wt% of B; balance aluminum.

[0005] In another prior art, a composition of the aluminum based alloy wire rod is disclosed. The aluminum based alloy rod includes 0.10-1.00 mass % Mg; 0.10-1.00 mass % Si; 0.01-1.40 mass % Fe; 0.000-0.100 mass % Ti; 0.000-0.030 mass % B; 0.00-1.00 mass % Cu; 0.00-0.50 mass % Ag and 0.00-0.50 mass % Au. In addition, the aluminum based alloy includes 0.00-1.00 mass % Mn; 0.00-1.00 mass % Cr; 0.00-0.50 mass % Zr; 0.00-0.50 mass % Hf; 0.00-0.50 mass % V; 0.00-0.50 mass % Sc; 0.00-0.50 mass % Co; 0.00-0.50 mass % Ni. The balance being Al and incidental impurities, wherein at least one of Ti, B, Cu, Ag, Au, Mn, Cr, Zr, Hf, V, Sc, Co and Ni is contained in the composition or none of Ti, B, Cu, Ag, Au, Mn, Cr, Zr, Hf, V, Sc, Co and Ni is contained in the composition.

[0006] The present composition of aluminum alloys mentioned in the prior arts and other prior arts bears several disadvantages. The traditional percentage proportions of Sc & Cd and other trace elements except Zr, Fe, Si, Cu, B disclosed in the prior arts leads to low thermal resistance and poor conductivity of overhead electric power conductors. This leads to low continuous operating temperature operation.

[0007] In light of the above stated discussion, there is a need for an aluminum alloy composition that overcomes the above stated disadvantages.

OBJECT OF THE DISCLOSURE

[0008] A primary object of the present disclosure is to provide an aluminum based Al3Zr alloy composition.

[0009] Another object of the present disclosure is to provide an aluminum based Al3Zr alloy composition for manufacturing high strength aluminum alloy conductors.

SUMMARY
[0010] In an aspect, the present disclosure provides an aluminum based Al3Zralloy composition for manufacturing an aluminum alloy conductor. The aluminum based Al3Zr alloy composition includes 99.25 to 99.5 % aluminum by weight. In addition, the aluminum based Al3Zr alloy composition includes 0.001 to 0.002 % boron by weight, 0.010 to 0.050 % copper by weight and 0.200 to 0.350 % zirconium by weight. Moreover, the aluminum based alloy Al3Zrcomposition includes 0.050 to 0.070 % silicon by weight and 0.150 to 0.190 % iron by weight. Moreover, the aluminum alloy conductor wire rod has a pre-defined ultimate tensile strength in a range of 150 Mega pascal (hereinafter as “MPa”) to 200 MPa.

[0011] In an embodiment of the present disclosure, the aluminum based alloy composition further includes up to 0.005 % magnesium by weight.

[0012] In an embodiment of the present disclosure, the aluminum based alloy composition further includes up to 0.001 % manganese by weight.

[0013] In an embodiment of the present disclosure, the aluminum based alloy composition further includes up to 0.002 % chromium by weight.

[0014] In an embodiment of the present disclosure, the aluminum based alloy composition further includes up to 0.014 % nickel by weight.

[0015] In an embodiment of the present disclosure, the aluminum based alloy composition further includes up to 0.001 % zinc by weight.

[0016] In an embodiment of the present disclosure, the aluminum based alloy composition further includes up to 0.001 % titanium by weight.

[0017] In an embodiment of the present disclosure, the aluminum based alloy composition further includes up to 0.011 % vanadium by weight.

[0018] In an embodiment of the present disclosure, the aluminum based alloy composition further includes up to 0.008 % tin by weight.

[0019] In an embodiment of the present disclosure, the aluminum based alloy composition further includes up to 0.002 % lead by weight.

[0020] In an embodiment of the present disclosure, the aluminum alloy conductor wire rod has a pre-defined conductivity in the range of 59.5 % to 60.5 % IACS. In addition, the aluminum alloy conductor has a pre-defined heat resistance in the range of 90 % to 94 %.

STATEMENT OF THE DISCLOSURE

[0021] The present disclosure relates to an aluminum based Al3Zr alloy composition for manufacturing an aluminum alloy conductor. The aluminum based Al3Zr alloy composition includes 99.25 to 99.5 % aluminum by weight. In addition, the aluminum based Al3Zr alloy composition includes 0.001 to 0.002 % boron by weight, 0.010 to 0.050 % copper by weight and 0.200 to 0.350 % zirconium by weight. Moreover, the aluminum based alloy Al3Zrcomposition includes 0.050 to 0.070 % silicon by weight and 0.150 to 0.190 % iron by weight. Moreover, the aluminum alloy conductor wire rod has a pre-defined ultimate tensile strength in a range of 150 MPa to 200 MPa.

BRIEFDESCRIPTIONOFFIGURES

[0022] Having thus described the disclosure in general terms, reference will now be made to the accompanying figures, wherein:

[0023] FIG. 1 illustrates a table for sample composition of an aluminum based Al3Zr alloy, in accordance with an embodiment of the present disclosure; and

[0024] FIG. 2 illustrates a table for one or more specifications of sample aluminum alloy conductor manufactured by utilizing aluminum based Al3Zr alloy, in accordance with an embodiment of the present disclosure.

DETAILEDDESCRIPTION

[0025] In the following description, for purposes of explanation, numerous specific details are set for thin order to provide a thorough understanding of the present technology. It will be apparent, however, to one skilled in the art that the present technology can be practiced without these specific details. In other instances, structures and devices are shown in block diagram form only in order to avoid obscuring the present technology.

[0026] Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in atleast one embodiment of the present technology. The appearance of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not other embodiments.

[0027] Moreover, although the following description contains many specifics for the purposes of illustration, any one skilled in the art will appreciate that many variations and/or alterations to said details are within the scope of the present technology. Similarly, although many of the features of the present technology are described in terms of each other, or in conjunction with each other, one skilled in the art will appreciate that many of these features can be provided independently of other features. Accordingly, this description of the present technology is set forth without any loss of generality to, and without imposing limitations upon, the present technology.

[0028] An aluminum based Al3Zr alloy is used for manufacturing an aluminum alloy conductor. The aluminum alloy conductor is employed to carry, transmit and distribute electrical power from one place to another place. Further, the aluminum based Al3Zr alloy includes aluminum as a major element. In addition, the aluminum based Al3Zr alloy includes one or more elements. In an embodiment of the present disclosure, the one or more elements are metallic elements. The one or more elements include but may not be limited to boron, copper, zirconium, silicon, iron, magnesium, zinc and the like. In an embodiment of the present disclosure, the one or more elements are added externally to obtain aluminum based Al3Zr alloy. In another embodiment of the present disclosure, the one or more elements are present as an impurity inside the aluminum based Al3Zr alloy.

[0029] An aluminum based alloy composition for the aluminum based Al3Zr alloy is described. The aluminum based alloy composition includes 99.25 to 99.50 % aluminum by weight. The aluminum based alloy composition includes 0.001 to 0.002 % boron by weight, 0.010 to 0.050 % copper by weight and 0.200 to 0.350 % zirconium by weight. In addition, the aluminum based alloy composition includes 0.050 to 0.070 % silicon by weight and 0.150 to 0.190 % iron by weight. Also, the aluminum based alloy composition includes up to 0.005 % magnesium by weight, up to 0.001 % manganese by weight and up to 0.002 % chromium by weight. Moreover, the aluminum based alloy composition includes up to 0.014 % nickel by weight, up to 0.001 % zinc by weight, up to 0.001 % titanium by weight and up to0.011 % vanadium by weight. Furthermore, the aluminum based alloy composition includes up to0.008 % tin by weight and up to 0.002 % lead by weight.

[0030] Hereinafter, reasons for limiting chemical compositions or the like of the aluminum based Al3Zralloy of the present disclosure will be described.

[0031] Boron possesses a refining property. The addition of boron as an alloying element refines the structure of a molten aluminum. In general, an alloying element is defined as a metallic or a non-metallic element added in a specified or standard amounts to a base metal to make an alloy. The presence of boron in the aluminum based Al3Zr alloy improves the conductivity of the aluminum based Al3Zr alloy. The presence of boron improves the conductivity of the aluminum based Al3Zr alloy by reducing quantity of a plurality of trace elements. The plurality of trace elements is present as an impurity in the aluminum ingot. In addition, the presence of boron reduces the quantity of the plurality of trace elements in the aluminum ingots by forming borides of trace elements.

[0032] In an embodiment of the present disclosure, the quantity of the boron present in the aluminum based Al3Zr alloy is about 0.001 % by weight to about 0.002 % by weight. The conductivity of the aluminum basedAl3Zr alloy decreases as the quantity of the plurality of trace elements is not reduced effectively and if the quantity of boron is less than 0.001 % by weight. The thermal resistance of the aluminum based Al3Zr alloy decreases as excess boron reduces the quantity of zirconium present in the aluminum based Al3Zr alloy and when the quantity of boron exceeds 0.002 % by weight.

[0033] Going further, copper possesses a strengthening property. The addition of copper as the alloying element improves tensile strength, impact resistance and bending fatigue resistance of the aluminum based Al3Zr alloy. In an embodiment of the present disclosure, the quantity of the copper present in the aluminum based Al3Zr alloy is about 0.010 % by weight to about 0.050 % by weight. The strengthening property of the aluminum based Al3Zr alloy is not effectively improved when the quantity of the copper is less than 0.030 % by weight. The thermal resistance and the conductivity of the aluminum based Al3Zr alloy decreases when the quantity of copper exceeds 0.050 % by weight.

[0034] Zirconium possesses thermal stability property. The addition of zirconium as the alloying element improves the thermal resistance of the aluminum based Al3Zr alloy. In an embodiment of the present disclosure, the quantity of the zirconium present in the aluminum based Al3Zr alloy is about 0.200 % by weight to about 0.350 % by weight. The addition of zirconium in an aforementioned quantity allows zirconium to form Al3Zr precipitates. The formation of Al3Zr precipitate improves thermal resistance of the aluminum based Al3Zr alloy. The Al3Zr precipitate does not form and sufficiently results in reduction of thermal resistance property of the aluminum based Al3Zr alloy when the quantity of zirconium is less than 0.200 % by weight. The Al3Zr precipitate crystallizes and does not disperse in the aluminum based Al3Zr alloy and reduces the thermal resistance of the aluminum based Al3Zr alloy when the quantity of zirconium exceeds 0.350 % by weight. In addition, the presence of zirconium in excess quantity results in the formation of a plurality of second phase particles of zirconium. The formation of the plurality of second phase particles lead to micro structural defects in the aluminum based alloy.

[0035] Going further, silicon possesses the strengthening property. The addition of silicon as the alloying element improves the tensile strength, the impact resistance of the aluminum based alloy. In an embodiment of the present disclosure, the quantity of silicon present in the aluminum based Al3Zr alloy is about 0.050 to about 0.070 % silicon by weight. The strengthening property of the aluminum based Al3Zr alloy is not effectively improved when the quantity of silicon is less than 0.050 % by weight. The thermal resistance and the conductivity of the aluminum based Al3Zr alloy decreases when the quantity of silicon exceeds 0.070 % by weight.

[0036] FIG. 1 illustrates a table 100 for sample composition of the aluminum based Al3Zr alloy, in accordance with an embodiment of the present disclosure. The sample composition of the aluminum based Al3Zr alloy includes 99.347 % by weight of aluminum, 0.001 % by weight of boron, 0.297 % by weight of zirconium, 0.043 % by weight of copper and 0.067 % by weight of silicon. In addition, the sample composition of the aluminum based Al3Zr alloy includes 0.185 % by weight of iron, 0.005 % by weight of magnesium, 0.001 % by weight of manganese and 0.002 % by weight of chromium. Moreover, the sample composition of the aluminum based Al3Zr alloy includes 0.014 % by weight of nickel, 0.001 % by weight of zinc, 0.001 % by weight of titanium and 0.011 % by weight of vanadium. Furthermore, the sample composition of the aluminum based Al3Zr alloy includes 0.000 % by weight of strontium, 0.008 % by weight of tin and 0.002 % by weight of lead.

[0037] FIG. 2 illustrates a table 200 for one or more specifications of sample aluminum alloy conductor manufactured by utilizing aluminum based Al3Zr alloy, in accordance with various embodiments of the present disclosure. In an embodiment of the present disclosure, the one or more specifications include values of a plurality of mechanical property, electrical property and thermal property associated with the aluminum alloy conductor. The mechanical property is ultimate tensile strength associated with the aluminum alloy conductor. The electrical property is conductivity associated with the aluminum alloy conductor. The thermal property is heat resistance associated with the aluminum alloy conductor.

[0038] Going further, the values of the plurality of mechanical property, the electrical property and the thermal property is associated with one or more diameters of the aluminum alloy conductor. In an embodiment of the present disclosure, diameter of the aluminum alloy conductor is 4.16 mm. In another embodiment of the present disclosure, the diameter of the aluminum alloy conductor is 4.39 mm. Furthermore, the plurality of values of the mechanical property, the electrical property and the thermal property is associated with one or more combinations of sample percentage proportions of aluminum, zirconium and copper.

[0039] In an example, an aluminum alloy conductor rod has a wire diameter of 4.16 mm. The aluminum alloy conductor includes 99.30 % aluminum by weight, 0.285 % zirconium by weight and 0.042 % copper by weight. The aluminum alloy conductor has the ultimate tensile strength of 182 Mega pascal (hereinafter as “MPa”). In addition, the aluminum alloy conductor wire rod has a conductivity of about 60.48 % IACS (International Annealed Copper Standard). In general, IACS is a unit of electrical conductivity for metals and alloys that is measured relative to a standard annealed copper conductor. For example, an IACS value of100%refers to a conductivity of5.80 × 107 Siemens per meter (58.0 MS/m) at 20 °C. Moreover, the aluminum alloy conductor wire rod has a heat resistance of about 93 %. In another example, an aluminum alloy conductor rod has a wire diameter of 4.39 mm. The aluminum alloy conductor wire rod include 99.447 % aluminum by weight, 0.288 % zirconium by weight and 0.038 % copper by weight. The aluminum alloy conductor wire rod has the ultimate tensile strength of 173 MPa. In addition, the aluminum alloy conductor wire rod has a conductivity of about 59.5 % IACS. Moreover, the aluminum alloy conductor has a heat resistance of about 92 %.

[0040] The foregoing descriptions of specific embodiments of the present technology have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present technology to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present technology and its practical application, to thereby enable others skilled in the art to best utilize the present technology and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the claims of the present technology.

[0041] While several possible embodiments of the invention have been described above and illustrated in some cases, it should be interpreted and understood as to have been presented only by way of illustration and example, but not by limitation. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments.