Aluminum and aluminum alloy drawn round wire
Aluminum and aluminum alloy drawn round wire is a round wire produced through a drawing process. It features uniform diameter, a smooth surface, and excellent electrical conductivity, making it widely used in wire and cable, electronics, and other fields. Pure aluminum drawn round wire has high conductivity and is a primary material for wire production. Aluminum alloy round wire, by adding small amounts of alloying elements (such as magnesium, silicon, and iron), maintains a certain level of conductivity while also improving strength and wear resistance, making it suitable for applications requiring mechanical stress. Based on diameter, drawn round wire can be categorized as thick, medium, and thin. Thin wire can be as small as 0.1mm or less, meeting the demands of precision electronic components.
The production process for drawn round aluminum and aluminum alloy wire is centered around multi-pass stretching, a process that requires precise control to ensure wire quality. First, aluminum ingots or aluminum alloy ingots are melted and cast into round billets. After annealing, the billets undergo preliminary stretching to produce thicker wire. The wire then enters a continuous stretching unit, where it is gradually stretched through a series of dies with different apertures. Each stretching pass reduces the wire’s diameter and increases its length. During the stretching process, the wire undergoes work hardening, requiring regular annealing to restore its plasticity and prevent breakage during stretching. To reduce die wear and improve the surface quality of the wire, a lubricant is used during stretching. Ultimately, after multiple stretching and annealing steps, a round wire meeting the required diameter is obtained. The wire then undergoes surface treatment, coiling, and other processes before passing inspection and leaving the factory.
In the wire and cable industry, aluminum and aluminum alloy drawn round wire are indispensable raw materials. Due to its excellent conductivity and low cost, pure aluminum round wire is widely used in low-voltage overhead lines and indoor wiring. For example, aluminum stranded wire, widely used in rural power grid renovations, is made by twisting multiple strands of pure aluminum drawn round wire together, ensuring both conductivity and mechanical strength. Aluminum alloy round wire is used in high-voltage and specialty cables. For example, 5056 aluminum alloy round wire, with its high strength and corrosion resistance, is suitable for overhead cables in coastal areas, offering protection from sea breezes and salt spray, extending its service life. Furthermore, in communication cables, some shielding layers are woven from aluminum round wire to provide electromagnetic shielding.
The electronics, electrical appliances, and instrumentation sectors demand extremely high precision from drawn aluminum and aluminum alloy round wire, making them the primary market for fine wire applications. In electronic devices, precision aluminum round wire is used to create contact leads for relays and sensor connectors. Its small diameter and excellent conductivity ensure stable transmission of electronic signals. For example, ultra-fine aluminum round wire is often used in camera modules and battery connectors in smartphones, saving space while meeting current transmission requirements. In instrumentation, aluminum round wire is used to create coils, windings, and other components. For example, the windings of small transformers use aluminum round wire, leveraging its excellent winding properties to increase winding density and reduce instrument size.
With the development of new energy and high-end manufacturing industries, the application areas of aluminum and aluminum alloy drawn round wire continue to expand. In new energy vehicles, the battery pack wiring harness uses highly conductive aluminum alloy round wire, which not only meets the needs of high current transmission, but also reduces wiring weight and improves energy efficiency. In photovoltaic inverters, aluminum round wire is used to make inductor coils. Its excellent conductivity and heat resistance ensure the efficient operation of the inverter. In addition, in the aerospace field, some equipment uses aluminum alloy round wire for conductors to withstand harsh environments such as high altitude, low temperature, and vibration. In the future, as the requirements for material performance increase, companies will further develop high-conductivity, high-strength aluminum alloy drawn round wire to promote its application in more high-end fields, and the market prospects are broad.
