| About this Abstract |
| Meeting |
2023 TMS Annual Meeting & Exhibition
|
| Symposium
|
Friction Stir Welding and Processing XII
|
| Presentation Title |
Copper-aluminum Hybrid Induction Motor Rotors Using Friction Stir Welding |
| Author(s) |
Hrishikesh Das, Piyush Upadhyay, Glenn Grant, John Agapiou, Blair Carlson |
| On-Site Speaker (Planned) |
Hrishikesh Das |
| Abstract Scope |
Replacement of copper end caps with Aluminum in rotor design has the potential to make induction motors lighter and cost-effective for EV applications. However, Al-Cu die casting is challenging. In a collaborative project, Friction stir welding is being evaluated as a viable method to produce a robust Al-Cu interface without the need for die casting. In this work, the copper shorting bars are perpendicular to the end cap and the end caps are made of multiple stacks of Al. Novel Al-Cu interface geometries/tool designs were developed to produce various Al-Cu bonded joints in a linear coupon scale. Several FSW strategies including single pass, 2 pass and 3 pass with a few tool designs have been evaluated. It was found that double pass friction stir welding provided excellent tensile strength with small variability. SEM/EDS analysis revealed a submicron level intermetallic layer at the Al-Cu interface. |
| Proceedings Inclusion? |
Planned: |