Investigating the mechanical, electrical and corrosion properties of as-cast Al-Grp-Ti composite for electrical conductor

Abstract Conventional aluminium conductors used in power transmission are challenged by a number of factors like high sag, thermal instability, and moderate strength which result in lower performance and durability. Thus, this study is motivated by the need to develop a more robust and sustainable Al-based composite conductor. Excellent strength, low density, electrically conductive and corrosion-resistant novel Al-Graphene-Ti composite was synthesized through scalable and affordable stir casting technique. In the experiment, five composite samples were produced varying the weight percent of Ti from 2–5. The tensile strength, microhardness, impact strength, water absorption, electrical conductivity and corrosion resistance of the samples were tested. Results showed that Sample 3 (Al–1Grp–3Ti) composite sample outperformed the whole samples in tensile strength and hardness as a result of homogenous dispersion of reinforcements, refinement of grains, and strong interfacial bonding. The hardness of the sample was 133.10 HV with an improvement of 127% relative to pure Al and electrical conductivity of 68% IACS with an improvement of 4% relative to pure Al. The corrosion resistance improved significantly but the impact strength declined. It was also observed that when the weight percent of Ti exceeded 3%, their properties deteriorated as a result of agglomeration of reinforcing phases. Hence, the research showcases the uniqueness of integrating graphene and Ti in Al matrix using innovative stir casting technique for sustainable and robust transmission conductors. The novelty is that the study was able to achieve a high strength, electrically conductive, and corrosion resistant material via in situ formation of Al 3 Ti intermetallic and homogenous dispersion of graphene. So, a unique lightweight, durable, and highly conductive material for Industry 4.0 transmission electrical conductor has been developed.