Development Status of Production Purification and Casting and Rolling Technology of Electrical Aluminum Rod

As the demand for lightweight and high-performance conductive materials grows in power transmission systems, aluminum alloy rods have emerged as a cost-effective and scalable alternative to copper conductors. This review systematically examines the development status and technological progress in the purification and casting–rolling processes used in the production of Electrical Round Aluminum Rods (ERARs). It explores current challenges in improving electrical conductivity and mechanical strength while addressing issues such as hydrogen and oxide inclusion removal, grain refinement, and impurity segregation. Key purification techniques—including flux refining, gas treatment, filtration, and rotary injection—are compared in terms of performance, cost, and environmental impact. The paper also analyzes different casting–rolling methods, including continuous casting and rolling, twin-roll casting, and extrusion processes, with attention to process optimization and equipment design. Furthermore, emerging applications of artificial intelligence (AI) in predictive modeling, defect detection, and process parameter optimization are highlighted, offering a novel perspective on intelligent and sustainable ERAR production. This paper aims to provide insights for facilitating the industrial-scale production and performance enhancement of ERAR materials.