Die Casting Copper Rotors - Copper Development Association

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IntroductionParticipants? CDA— program management & technical direction? ICA— major copper industry support? US Dept. of Energy— NICE 3 /OIT contributed $425,000? Motor Manufacturers (multiple)? Air Conditioning & Refrigeration Institute? CDA Members – alloy testing suggestions? Formcast— die casting/technology capability
IntroductionObjectives? <strong>Development</strong> of mold (die) materials and processingfor cost-effective copper motor rotor manufacturing? Electrical energy efficiency improvement
Page 1 and 2: Die Cast Copper Motor RotorWorkshop
Page 3: IntroductionProgram initiation - Ba
Page 7: IntroductionAdvantages to motor per
Page 10 and 11: Cracking -Thermal Expansion & Contr
Page 12: Die Materials TestingH-13 tool stee
Page 22 and 23: Predicted Temperature Profiles
Page 24 and 25: The Die Casting ProcessSystem desig
Page 26 and 27: The Die Casting ProcessInductotherm
Page 28 and 29: The Die Casting ProcessApplying dry
Page 30 and 31: The Die Casting ProcessTransferring
Page 32 and 33: The Die Casting ProcessEjecting cop
Page 34 and 35: Testing Die MaterialsDr. John G. Co
Page 36 and 37: Testing of Die Materials - H-13 Ste
Page 44 and 45: Testing of Die Materials - CVD-W on
Page 46 and 47: Testing of Die Materials - InconelV
Page 48 and 49: Testing of Die Materials - InconelP
Page 50 and 51: Testing of Die Materials - TZM & An
Page 52 and 53: Testing of Die Materials - TZM & An
Page 54 and 55:
Testing of Die Materials - Nickel A
Page 56 and 57:
AlloyDie Materials TestingNickel-ba
Page 58 and 59:
AlloyDie Materials TestingSuperallo
Page 60 and 61:
Die Materials TestingConclusions -
Page 62 and 63:
Die Casting Copper RotorsMaster die
Page 64 and 65:
Die Casting Copper RotorsLarger Ind
Page 66 and 67:
Die Casting Copper RotorsArbor (Man
Page 68 and 69:
Die Casting Copper RotorsAssembled
Page 70 and 71:
Die Casting Copper RotorsInserting
Page 72 and 73:
Die Casting Copper RotorsCopper pel
Page 74 and 75:
Die Casting Copper RotorsPouring co
Page 76 and 77:
Die Casting Copper RotorsEjecting r
Page 78 and 79:
Die Casting Copper RotorsWater-quen
Page 80 and 81:
Die Casting Copper RotorsCross-sect
Page 82 and 83:
Rotor Steel Specification for Coppe
Page 84 and 85:
Capabilities for Future Die Casting
Page 86 and 87:
Motor Test ResultsMr. Darryl Van So
Page 88 and 89:
Diminishing ReturnsLossesWe arehere
Page 90 and 91:
Motor TestsRotor I 2 R Losses (Watt
Page 92 and 93:
Motor TestsCopper rotor consistency
Page 94 and 95:
Motor TestsRotor Cost Implications?
Page 96 and 97:
15 kW Motor - Past, Present and Fut
Page 98 and 99:
Principles of die casting technolog
Page 100 and 101:
Abbreviations for die castingA = ar
Page 102 and 103:
Gate velocity v MAV MA=____________
Page 104 and 105:
Metal flow rate Q mm AQ M=? ?t Fm p
Page 106 and 107:
Runner cross section A kA KA K= 1.6
Page 108 and 109:
Sankey diagram
Page 110 and 111:
Heat Conduction Q IQ l= ? w* A w* (
Page 112 and 113:
The three cooling areas
Page 114 and 115:
Insulation material
Page 116 and 117:
Insulation material
Page 118 and 119:
Electrical heaters
Page 120 and 121:
Electrical heaters
Page 122 and 123:
The shot sleeve design
Page 124 and 125:
The die design
Page 126:
The die design
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Die Casting Copper Rotors - Copper Development Association

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