Copper-clad thermally stable Al-Zr wire, produced via copper electrodeposition

Producing of the copper-clad aluminium wire made of Al-0.4Zr alloy via electrodeposition was studied. In order to ensure the adhesion of the copper after deposition, the intermediate Ni layer was applied to the aluminium wire surface. Formation of the composite wire with aluminium alloy core and copper sheath resulted in the increase of the ultimate tensile strength from 175 to 233 MPa, while also slightly decreasing electrical conductivity and notably decreasing ductility from 6 to 3 %. Annealing at 300 °C for 1 hour was performed to the composite wire to increase its ductility. Annealing resulted in the recovery of the mechanical properties back to the level of initial aluminium alloy wire, while electrical conductivity increased by 3.5 % IACS, allowing the newly produced composite wire to compete with the commercially produced copper-clad aluminium wires.