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Aluminum-based alloys are highly sought after as lightweight alternatives in electric grid applications. Improving the electrical conductivity of aluminum alloys has the potential to increase the energy efficiency of power transport. The hot extrusion process was used to synthesize AA1100 alloy with low-cost reduced graphene oxide nanoparticles to manufacture ultra-conductive aluminum composites in this study. The effects of graphene content on the electrical and mechanical performance of the composites were evaluated. The macroscale AA1100/graphene wires demonstrated a 2.1% enhancement in electrical conductivity at 20 °C, while the ultimate tensile strength increased by 6.1%. A Zener-Hollomon model was used to confirm the in-process exfoliation of the agglomerated graphene nanoparticle feedstock into high electrical conductivity graphene-like flakes during extrusion. The graphene-like flakes may …