Metallurgical aspects in high volume copper bonding

Current motor manufacturing practices involve the rapid and precise winding of insulated copper wire to form the field coil on the armature. Immediately after winding, the copper wires are bonded to the tangs of the commutator. Adequate bonding between the field coil wire and the commutator at the tang is necessary for proper motor operation. Manufacturing costs and product quality are important issues. Results of characterization studies involving typical bonds produced in this manner are discussed.