Breaking Boundaries: Graphene-Enhanced Copper Wires Transform Electrical Conductivity

Researchers at the US Department of Energy’s Pacific Northwest National Laboratory (PNNL) have made a groundbreaking discovery regarding the conductivity of electrical wires. Their findings, published in Materials & Design, indicate that adding graphene, a common carbon compound, to copper wires can significantly enhance their performance, contrary to conventional wisdom.

Led by Keerti Kappagantula, the team found that incorporating graphene into copper wires through PNNL's patented ShAPE (Shear Assisted Processing and Extrusion) platform resulted in remarkable improvements. Specifically, the addition of just 18 parts per million of graphene to electrical-grade copper led to an 11% decrease in the wires' temperature coefficient of resistance. This decrease, importantly, did not compromise the wires' electrical conductivity at room temperature.

This discovery challenges previous notions about the behavior of metal conductors, which typically experience increased resistance when additives are introduced. Instead, the copper-graphene composite demonstrated enhanced conductivity, offering promising implications for various applications.

For instance, electric vehicle motors, which heavily rely on copper wiring, could see significant efficiency gains. A mere 11% increase in electrical conductivity translates to a 1% efficiency improvement in motor performance. Moreover, the composite's ability to maintain conductivity at higher temperatures could revolutionize motor design, allowing for operation in more extreme conditions without sacrificing efficiency.

Beyond electric vehicles, the potential applications of this discovery are extensive. Coiled copper wire forms in electric motors and generators, as well as wiring in transmission lines and buildings, stand to benefit from the enhanced conductivity offered by the copper-graphene composite.

Looking ahead, the research team plans to further tailor the composite material and assess additional properties such as strength, fatigue, corrosion, and wear resistance. These steps are crucial for qualifying the material for widespread industrial use.

The PNNL researchers' innovative approach to enhancing electrical conductivity opens new doors for efficiency and performance improvements across various industries, from transportation to infrastructure.