Abstract: The method of electromagnetic casting (EMC) was used to produce the long-length rod billet (with a diameter 12 mm) of aluminum alloy containing 0.6 wt.% Zr, 0.4%Fe, and 0.4%Si. The combination of high cooling rate (104 K/s) during alloy solidification and high temperaturebefore casting (830oC) caused zirconium to dissolve almost completely in the aluminum solid
solution (Al). Additions of iron and silicon were completed in the uniformly distributed eutectic Al8Fe2Si phase particles with an average size of less than 1 m. Such fine microstructure of the experimental alloy in as-cast state provides excellent deformability during wire production using direct cold drawing of EMC rod (94% reduction). TEM study of structure evolution in the as-drawn
3 mm wire revealed the onset of Al3Zr (L12) nanoparticle formation at 300 C and almost-complete decomposition of (Al) at 400 C. The distribution of Zr-containing nanoparticles is quite homogeneous, with their average size not exceeding 10 nm. Experimental wire alloy had the ultimate tensile strength
(UTS) and electrical conductivity (EC) (234 MPa and 55.6 IACS, respectively) meeting the AT2 type specification. At the same time, the maximum heating temperature was much higher (400 versus 230 C) and meets the AT4 type specification.