Fault investigations on die-cast copper rotors

It has been long known to the market that, the use of copper in the rotor in place of aluminium, taking advantage of copper's high conductivity, can be an economic solution for various applications, including electric vehicle, in the development of energy efficient motors. In comparison to aluminium, copper die-casting is extremely difficult to perform due to its high density, viscosity and melting point. Owing to these reasons, the copper die-cast rotors will evince several manufacturing problems. The objective of this paper is to identify the various defects in the manufacturing of copper die-cast rotor, and identify the lamination-coating-condition that sustains copper die-cast pressure and temperature. This paper evaluates the effectiveness of lamination coating on limiting the eddy current loss, and the recoating process to improve, in case the eddy current losses are in excess due to copper die-casting.