Interface-engineered al/SWCNT-resin composite wires with improved electrical and mechanical performance

This study presents the fabrication and characterisation of novel ultra-conductive aluminium wires achieved through the conformal coating of single-walled carbon nanotubes (SWCNTs) in a unique sandwich composite structure (Al/SWCNT-resin). Electrothermal characterisation results indicated a significant enhancement in thermal stability and effective suppression of thermal runaway at high current densities in the composite wires compared to pure Aluminium, despite a marginal increase in electrical resistivity. Notably, the Al/SWCNT-resin composite wire exhibited a resistivity of 2.965 μΩ cm and ampacity of 1.45 × 104 A cm−2. These findings highlight the substantial potential of the Al/SWCNT-resin composite wire as an advanced conductor for high-current applications that require superior thermal and long-term durability. © 2025 The Authors.