Overhead conductor heating chamber and temperature effects on the fatigue life of aluminum alloy 6201‐T81 conductors.

This work investigates the impact of temperature on the fatigue life All Aluminum Alloy Conductors (AAAC) made of 6201‐T81. A heating chamber was developed to simulate thermal effects induced by electric current passage. Wöhler fatigue curves were generated under isothermal conditions at 75 and 150°C and later compared with the one at 20°C. The conductor exhibited similar fatigue life at 20 and 75°C; however, a significant increase of life was observed for tests at 150°C. Hardness tests and failure analysis of wire breakages were carried out on samples extracted from the conductor coil and on artificially aged samples maintained at controlled temperatures. The analyses revealed that at a temperature of 150°C, there is formation of small precipitates of magnesium and silicon within the aluminum matrix, which impeded the propagation of discontinuities, increasing the material's hardness and fatigue resistance. Highlights: The designed heating chamber simulates thermal effects during fatigue tests on conductors.S‐N curves at 20, 75, and 150°C reveal enhanced conductor life at higher temps.Failure analysis present similar patterns across all temperature fatigue failures.Samples' hardness on conductor wires shows a temperature‐induced mechanical changes. [ABSTRACT FROM AUTHOR]