Introduction

As the new energy sector continues to grow, wind power generation requires high-performance flexible cables that can withstand harsh environmental conditions, including extreme cold and repeated torsion (twisting) cycles. Traditionally, copper conductors have been used in these cables due to their excellent conductivity and mechanical properties. However, aluminum alloy conductors have emerged as a promising alternative due to their lower cost, lightweight nature, and recent improvements in mechanical strength and flexibility.

This article provides an in-depth analysis of a low-temperature torsion test conducted on aluminum alloy conductors used in wind power cables. The study evaluates:

• Fracture behavior after torsion testing
• Changes in mechanical and electrical properties
• Material and process innovations to improve performance

By analyzing these factors, we assess whether aluminum alloy conductors can effectively replace copper conductors in new energy applications.

1. The Need for Aluminum Alloy Conductors in Wind Power Cables

1.1 Advantages of Aluminum Alloy over Copper

Copper conductors are widely used due to their high conductivity and durability. However, aluminum alloys offer several key advantages:

➡ Conclusion: Aluminum alloy conductors offer a significant cost and weight advantage, making them ideal for large-scale wind farm installations.

2. Experimental Setup: Low-Temperature Torsion Test

2.1 Sample Preparation and Material Selection

To evaluate the torsion resistance of aluminum alloy conductors, two common alloy compositions were selected:

1. 6101 aluminum alloy – High strength, good conductivity
2. 8030 aluminum alloy – Superior ductility, moderate conductivity

➡ Key Design Insight: A hybrid structure combining 6101 and 8030 alloys was tested to optimize torsion resistance and electrical performance.

2.2 Testing Procedure

• Test Conditions: The samples were exposed to -55°C in a controlled temperature chamber.
• Torsion Cycles:
  • 4 clockwise turns, then 4 counterclockwise turns (1 cycle).
  • Repeated for 2,000 cycles per sample.
• Evaluation Metrics:
  • Fracture location and behavior
  • Mechanical properties before and after testing
  • Electrical conductivity changes

3. Test Results and Analysis

3.1 Fracture Behavior After Torsion Test

After 2,000 torsion cycles, the samples were examined for structural integrity. Key observations included:

• Outer strands remained intact, but core strands showed significant compression deformation.
• Some fractures occurred in core wires, due to stress concentration.
• Surface cracks were observed, indicating material fatigue.

➡ Conclusion: 8030 alloy exhibited slightly better fracture resistance, making it more suitable for low-temperature applications.

3.2 Changes in Mechanical Properties

Mechanical testing before and after the torsion test showed a moderate reduction in strength and ductility:

➡ Key Finding: Aluminum alloy conductors maintain mechanical strength but lose ductility over time, which may impact long-term performance.

3.3 Changes in Electrical Properties

One of the main concerns when replacing copper with aluminum is the impact on electrical resistance.

➡ Conclusion: Minimal impact on conductivity was observed, confirming that aluminum alloys can reliably conduct electricity even after torsion stress.

4. Key Engineering Insights and Recommendations

4.1 Optimization Strategies for Improved Performance

• Material Optimization: A hybrid approach using 8030 core strands for flexibility and 6101 outer strands for strength improves overall performance.
• Process Improvements:
  • Heat treatment reduces residual stress.
  • Protective coatings improve corrosion resistance.
• Cable Structure Adjustments:
  • Larger conductor cross-sections can compensate for lower conductivity.
  • Stranded configurations enhance torsion resistance.

4.2 Potential Industry Applications

➡ Final Verdict: Aluminum alloy conductors are well-suited for wind and solar energy applications but may not fully replace copper in high-voltage or extreme mechanical stress environments.

5. Conclusion

The low-temperature torsion test confirmed that aluminum alloy conductors are a viable alternative to copper in wind power cables, offering:
✔ Cost and weight advantages
✔ Adequate torsion resistance
✔ Minimal impact on electrical performance

Final Recommendation

✅ Adopt aluminum alloy conductors for wind and solar power cables.
⚠ Further testing is needed for electric vehicle and high-voltage applications.

With ongoing material innovations, aluminum alloys have the potential to replace copper in many next-generation energy applications, contributing to more sustainable and cost-effective power transmission solutions.

Keywords

• Aluminum Alloy Conductors
• Wind Power Cables
• Torsion Testing
• Low-Temperature Performance
• Electrical Conductivity

References

1. Su H., Li G., Pang B. (2025). Low-Temperature Torsion Test of Aluminum Alloy Conductors for New Energy Cables. Wire & Cable, 68(1), 49-54. DOI: 10.16105/j.dxdl.1672-6901.20240088
2. GB/T 29631-2013 – Wind Power Flexible Cables Torsion Test Standard
3. GB/T 3048.2-2007 – Electrical Performance Testing of Conductors