Recent Advancements in Hairpin Welding: Manufacturing and Properties

Abstract

In the last decade or so, the technology in electric vehicles has advanced significantly including increased battery range, faster charging, wireless charging, battery management, battery weight reduction, power and efficiency of the electric motor, and many others. There are two main components in the electric motor, namely, rotor and stator. Hairpins are critical part of a stator. They are made of pure copper. One of the important processes in the fabrication of a stator is connecting/welding the individual hairpin. In this paper, a brief description of hairpin manufacturing based on the published articles and the results from more recent investigation, particularly the welding aspect is provided.