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<p>Electrical round aluminum rods (ERARs) are crucial components in power transmission, where balancing electrical conductivity, tensile strength, and ductility is essential. Although the effects of various alloying elements on these properties have been studied, the influence of Fe and Mn and their interactions in the specific context of industrial ERARs has not been sufficiently explored. In this study, we first analyzed the impact of different alloying elements and identified Fe and Mn as the key contributors to the performance of ERARs. Based on this finding, response surface methodology (RSM) was employed to quantitatively model the synergistic effects of Fe and Mn fluctuations on resistivity, tensile strength, and elongation. The results demonstrate that Fe and Mn significantly increase resistivity (i.e., decrease conductivity) and tensile strength, but negatively affect elongation. Through RSM optimization, the optimal composition of 0.163&#xa0;wt.% Fe and 0.0033&#xa0;wt.% Mn was identified, resulting in predicted properties of 27.456&#xa0;nΩ&#xa0;m resistivity, 105.318&#xa0;MPa tensile strength, and 18% elongation. This study provides a practical framework for balancing electrical and mechanical properties in ERARs, offering valuable insights and guidance for industrial composition optimization, with a methodology applicable to other alloy systems.</p> Graphical Abstract <p></p>

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Optimization of Composition and Performance of Electrical Round Aluminum Rods Using Response Surface Methodology

  • 期刊论文

  • 发表日期：

    2026年4月28日

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  • Jiajun Jiang,
  • Huixin Jin

摘要

Electrical round aluminum rods (ERARs) are crucial components in power transmission, where balancing electrical conductivity, tensile strength, and ductility is essential. Although the effects of various alloying elements on these properties have been studied, the influence of Fe and Mn and their interactions in the specific context of industrial ERARs has not been sufficiently explored. In this study, we first analyzed the impact of different alloying elements and identified Fe and Mn as the key contributors to the performance of ERARs. Based on this finding, response surface methodology (RSM) was employed to quantitatively model the synergistic effects of Fe and Mn fluctuations on resistivity, tensile strength, and elongation. The results demonstrate that Fe and Mn significantly increase resistivity (i.e., decrease conductivity) and tensile strength, but negatively affect elongation. Through RSM optimization, the optimal composition of 0.163 wt.% Fe and 0.0033 wt.% Mn was identified, resulting in predicted properties of 27.456 nΩ m resistivity, 105.318 MPa tensile strength, and 18% elongation. This study provides a practical framework for balancing electrical and mechanical properties in ERARs, offering valuable insights and guidance for industrial composition optimization, with a methodology applicable to other alloy systems.

Graphical Abstract