Low-cost heat-resistant Al-Sc-Zr-Fe conductor wires were successfully manufactured by continuous rheo-extrusion process, and the mechanical and conductive properties of the materials were analyzed and compared after three different thermo-mechanical treatment methods. The coarse plate-shape Al₃Fe phase transformed to small sized rod-like phase after solid solution treatment at 630 °C for 21 h. Direct aging treatment at 300 °C for 24 h led to the refinement and spheroidization of Al₃Fe phase with a diameter of 200 nm. After the subsequent aging treatment at 300 °C for 24 h, the tensile strength and conductivity of the alloy wire significantly increased due to the homogeneous precipitation of the coherent spherical Al₃(Sc, Zr) phase with an average size of 15 nm. The tensile strength, elongation, and conductivity of the alloy conductor wire after optimized thermo-mechanical treatment reached 165.7 MPa, 7.3%, and 60.26% International Annealed Copper Standard (IACS), respectively. The thermal resistance of the present alloy wire was superior to that of standard AT1 type alloy conductor according to IEC international standard.

To reveal the formation and wear mechanisms of rheo-formed aluminum alloy - B₄C composites, A356 alloy − 10 mass% B₄C composite material was fabricated by semi-solid stirring rheo-casting and rolling process. The presence of Al₃BC was confirmed by XRD analysis and hinted that chemical bonding formed at interfaces between aluminum matrix and B₄C particles. Tensile test results demonstrated that addition of B₄C facilitated improving the tensile strength by refining matrix and providing particle strengthening. Failure tests revealed that the failure type of the composite transferred from interfacial debonding to particle cracking with increasing wear load. The wear rate of the composite was approximately 48% lower than that of aluminum alloy under 60 N load. The friction coefficient of the composite under 60 N load also significantly decreased due to formation of B₂O₃and H₃BO₃as solid lubricants.