Graphene-Enhanced Composite for High-Temperature Electrical Conductors

As technology advances in the military, aerospace and electric vehicle sectors, there is increasing demand for electrical conductors capable of operating at high temperatures. Copper is the most common electrical conductor used in various applications ranging from communication cables and power distribution grids, to electrical motors that power factories and electric vehicles, but it is reaching its functional limits. While copper-based metal composite conductors are considered promising, interfacial separation, resulting in lower electrical conductivity has plagued research groups. New, advanced conductors are needed to meet the demanding requirements that traditional copper simply cannot fulfill.

 

Researchers at Arizona State University have developed an advanced electrical conductor composed of copper layered with nickel, silver, and graphene shells, designed to maintain low resistivity and high current density in extreme temperature environments ranging from 550 to 850°C. Combining experimental analysis with molecular dynamics and finite element simulations, this composite leverages graphene’s unique diffusion barrier properties to significantly reduce metal interdiffusion and preserve structural integrity. Experimental and theoretical studies show that the embedded graphene layer results in significant enhancements to the wire compared to just NiGCu wire.

 

This multilayered composite conductor integrates Ni, Ag, Cu and Graphene to deliver unprecedented thermal stability and electrical conductivity at ultrahigh temperatures.

 

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