Die Casting Copper Motor Rotors: Mold Materials and Processing for Cost-Effective Manufacturing

Peters, D. T.; Cowie, John G.; Brush, Edwin F.

doi:10.1007/978-3-642-59785-5_5

Cited by 6 publications

(4 citation statements)

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“…Copper rotor casting experience and performance of motors equipped with copper rotors are detailed in another paper in this conference. At the 1999 EEMODS conference, a progress report on the die material investigation was presented [1]. This paper updates the results presented in 1999 and elaborates on the die failure mechanism and how die life can be substantially extended.…”

Section: Introductionmentioning

confidence: 59%

Application of High-Temperature Mold Materials to Die Cast Copper Motor Rotor for Improved Efficiency

Cowie¹,

Brush²,

Peters³

et al. 2003

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Section: Introductionmentioning

confidence: 59%

Application of High-Temperature Mold Materials to Die Cast Copper Motor Rotor for Improved Efficiency

Cowie¹,

Brush²,

Peters³

et al. 2003

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“…In consequence, the electrical steel sheets composing the rotor are subject to a thermal shock [20] but the melting temperature of aluminium (600 • C) is low enough so that they are not damaged during the process. The melting temperature of copper being way higher (1083 • C) , building a squirrel cage cast in copper implies the process to be performed at a temperature between 1100 • C and 1200 • C. Hence, the electrical steel sheets are subject to a way more important and faster thermal shock [21]- [24] whose effects can differ according to their grade [25]- [30]. On one hand, a deterioration in terms of core losses was observed for the fully processed electrical steel for an annealing temperature above 700 • C. On the other hand, an improvement of magnetic properties is noted for the semi processed steel for a temperature above 1000 • C. Moreover, no matter the grade, the thermal shock often leads to a shorting of the electrical steel sheets on the contact are with bar conductors as shown in Fig.…”

Section: Die Cast Squirrel Cagementioning

confidence: 99%

Increasing the Energy Efficiency of Induction Machines by the Use of Grain-Oriented Magnetic Materials and Die Casting Copper Squirrel Cage in the Rotor

Mallard

Parent

Demian

et al. 2019

IEEE Trans. on Ind. Applicat.

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This paper deals with an induction machine whose squirrel cage is made of copper obtained by die casting process. The major issue of this process is the thermal shock suffered by the laminations, leading to the deterioration of insulation coating as well as the generation of interbar currents, those currents being responsible for addition stray losses. This issue can be counteracted by using grain oriented laminations on the rotor. In particular, the paper highlights that due to the specificity of the insulation coating of that kind of electrical steel it does not suffer from the thermal shock. It is shown that using a squirrel cage made of copper combined to grain oriented laminations in the rotor leads to a decrease of both core losses and stray load losses and an increase of the efficiency of 1.6%.

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“…10,[12][13][14][15][16] The titanium-zirconium-molybdenum-based high temperature alloy (TZM) has shown encouraging results 8 but suffers extensive oxidation. 17 Silicon nitride (Si 3 N 4 )-based materials show exceptional fracture toughness and thermal shock resistance as well as high strength but are sensitive to oxidation and corrosive attack above 1100uC. 18 The present work was undertaken to explore the potential of a Ni-based superalloy, Inconel 617 alloy, reported to exhibit superior thermal fatigue resistance in demanding tooling applications.…”

Section: Introductionmentioning

confidence: 99%

Ni-based superalloy as a potential tool material for thixoforming of steels

Birol¹

2009

Ironmaking & Steelmaking

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Semisolid processing, already a well established manufacturing route for the production of intricate, thin walled aluminium and magnesium parts with mechanical properties as good as forged grades, faces a major challenge in the case of steels. The tool materials must withstand complex load profiles and relatively higher forming temperatures for thousands of forming cycles for this near-net shape process to be attractive for steels on an industrial scale. The potential of a Ni-based superalloy, Inconel 617, reported to exhibit superior thermal fatigue resistance in demanding tooling applications, was investigated. The response to thermal cycling of this alloy at high temperatures was compared with that of X38CrMoV5 hot work tool steel widely used in the manufacture of conventional forging dies. The favourable thermophysical properties of the latter were completely negated by its limited temper resistance, while the Inconel 617 alloy responded to thermal cycling by the usual heat cracking mechanism.

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Die Casting Copper Motor Rotors: Mold Materials and Processing for Cost-Effective Manufacturing

Cited by 6 publications

References 0 publications

Application of High-Temperature Mold Materials to Die Cast Copper Motor Rotor for Improved Efficiency

Application of High-Temperature Mold Materials to Die Cast Copper Motor Rotor for Improved Efficiency

Increasing the Energy Efficiency of Induction Machines by the Use of Grain-Oriented Magnetic Materials and Die Casting Copper Squirrel Cage in the Rotor

Ni-based superalloy as a potential tool material for thixoforming of steels

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