With the rapid transition of power transmission systems toward higher capacity, longer distance, and improved efficiency, aluminum alloys from the 6xxx (Al–Mg–Si) and 8xxx (Al–Fe) series have become key structural materials for overhead conductors and power cables due to their low density, cost effectiveness, and favorable strength–conductivity balance. Compared with traditional steel-reinforced conductors, optimized aluminum alloy conductors can reduce structural weight by approximately 30–40% and installation cost by about 20–30%, while maintaining comparable current-carrying capacity. This review systematically focuses on modification methods and research progress of aluminum alloy cores for electric wires and cables. The strengthening characteristics of 6xxx alloys (heat-treatment responsiveness and precipitation strengthening) and the creep-resistance stability of 8xxx alloys are comparatively analyzed. Four core performance requirements—high electrical conductivity, mechanical strength, creep resistance, and corrosion resistance—are summarized as evaluation criteria for conductor applications. Particular emphasis is placed on three major modification strategies: (1) microalloying (e.g., Zr, Sc, rare earth elements) for precipitation and dispersoid stabilization; (2) thermomechanical process optimization for grain refinement and strength–conductivity balance; (3) composite reinforcement for high-temperature and ultra-high-strength applications. Quantitative literature data indicate that microalloying and process optimization typically achieve 15–40% strength improvement with conductivity variation within 3–5% IACS, while composite strategies may provide 30–80% strength enhancement but often at the expense of 5–20% conductivity reduction. The distinct applicability of 6xxx and 8xxx alloys under different service conditions is clarified, providing guidance for conductor material selection. Finally, future research directions—including precise composition–process integration, advanced thermomechanical control, and scalable modification technologies—are proposed to support high-performance, cost-effective, and large-scale deployment of aluminum alloy conductors.
Deng et al. (Sun,) studied this question.