Production and Characterization of Highly Conductive Aluminum Metal for Electric Motor Applications

The aim of this research is to produce and develop high-conductive and non-magnetic Al-based materials used in industrial rotors to reduce rotor conductor losses and increase motor efficiency. To achieve this, ETIAL 7 Al metal was melted together with AlB₂ and AlB₁₂ inoculant materials at individually added proportions (ranging from approximately 0.025-0.300%) using an induction melting furnace. The removal of boron from Al metal was achieved by the interaction of boron with impurity elements at high temperatures and the formation of borides. Low-density metal borides precipitated into slag and high-density metal borides precipitated at the bottom of the molten metal in the induction furnace. As a result, the metal was rendered non-magnetic and its conductivity increased by removing impurity elements in the Al metal. After the casting process, the metal underwent heat treatment to obtain certain textures in the structure, which further enhanced its conductivity at desired directions. The elemental analysis, phase structure, chemical state, microstructural, electrical, and magnetic properties of the produced Al materials were characterized by using OEM, XRD, XPS, SEM-EDS, IA, and VSM. This study has successfully produced extra-high-conductivity and non-magnetic materials with an innovative approach, without changing the system, and in a cost-efficient manner compared to the current situation. These materials can be used to increase the efficiency of electric motors.