A Sustainable Microstructure Modification‐Based Design of Al‐Si Alloys for Energy Efficient Electric Power Transmission and Distribution

Power transmission and distribution systems need to be more efficient and sustainable to meet the growing electricity demand. The high conductivity of aluminum alloys is advantageous for power transmission. The present work demonstrates how the size, shape, and distribution of phases influence the electrical and thermal conductivity of a hypoeutectic Al‐Si alloy power connector. The addition of Al‐10 wt% Sr to Al‐10.5 wt% Si reduces the size of eutectic Si from 15 ± 8 μm to 0.75 ± 0.2 μm and β‐(Al‐Fe‐Si) phases from 52.85 ± 7 μm to 35.79 ± 3 μm, while slightly increasing the secondary dendrite arm spacing from 40.5 ± 3 μm to 55.2 ± 5 μm. These modifications increase the thermal conductivity from 111 to 127 W mK −1 , which enhances the current density of the power connector assembly from 1.7 × 10 7 to 2.1 × 10 7 A m −2 , improving its ampacity. Additionally, the Sr‐modified alloy exhibits superior corrosion resistance, with the corrosion rate decreases from 0.0416 to 0.012 mm year −1 . These results are supported by finite element simulations and experimental validation, which show that microstructure optimization enhances electrical and thermal conductivity while reducing energy losses. This approach lowers the electricity demand, decreases greenhouse gas emissions, and minimizes the environmental impact of frequent replacements.