Inertia welding for assembly of copper squirrel cages for electric motors

The automotive industry is developing designs and manufacturing processes for new generations of electric motors intended for use in hybrid and electric vehicles. There is interest in replacing the aluminum traditionally used in induction motor rotors with copper to improve motor capability. This paper focuses on solid-state welding to join copper end rings to copper spokes in the fabrication of copper rotors. Inertia friction welding was explored to examine weldability of these copper components. A better understanding of inertia welding characteristics will help the advancements in its application for induction rotors. The limitations of this application are discussed.