Components and the manufacture thereof via welding with reduced alloy-depletion

Patent metadata

Field	Value
Publication number	US-12589433-B2
Application number	US-202318215590-A
Country	US
Kind code	B2
Filing date	Jun 28, 2023
Priority date	Sep 26, 2019
Publication date	Mar 31, 2026
Grant date	Mar 31, 2026

Abstract

Systems and methods form induction rotors by performing isostatic pressing (HIP) to weld clad to a shaft, which allows for scaling the manufacturing of solid steel rotors, as compared to conventional techniques. In examples, the rotors are designed for high-speed motors and may include recessed short circuit rings and/or end rings. An exemplary process molds an alloy powder into cladding such that heretofore unachievable rotor designs are achievable according to systems and methods described herein. In examples, a thin source-layer is introduced to welding zones, thereby enriching and strengthening the resulting joint at welding zones. The source-layer may be introduced by adding an intermediate layer comprising the source material between the materials being welded. The reduced alloy-depletion welding disclosed herein strengthens the welding area joints and provides for the manufacture of component designs, which were previously unachievable due to alloy-depletion weaknesses and environmental constraints.

First claim

What is claimed is:

1 . An induction rotor for a motor comprising:
a steel rod having a surface and a diameter, wherein the surface includes longitudinally extending grooves formed along at least a portion of the surface, and the diameter of the steel rod varies along a longitude of the steel rod; a conductive cladding comprising a clad material, the conductive cladding surrounding the grooves on the steel rod and the surface of the steel rod between the grooves; end rings positioned at opposite ends of the conductive cladding and; an axial conductor comprising a unitary layer formed by the clad material filling the grooves of the steel rod, wherein the conductive cladding forms recessed short circuit rings on the steel rod.

2 . The induction rotor of claim 1 , wherein the steel rod further comprises shoulders.

3 . The induction rotor of claim 1 , wherein the conductive cladding is comprised of at least one of a cylinder, a plurality of bars, or a powder.

4 . The induction rotor of claim 3 , wherein the conductive cladding is copper.

5 . The induction rotor of claim 3 , wherein the rotor includes an intermediate layer between the steel rod and the conductive cladding.

6 . The induction rotor of claim 5 , wherein the intermediate layer is comprised of at least one of nickel or chromium.

7 . An induction rotor for a motor comprising:
a steel rod having a surface and a diameter and shoulders, wherein the diameter of the steel rod varies along a longitude of the steel rod; a conductive cladding comprising a clad material, the conductive cladding surrounding the surface of the steel rod and the shoulders; and wherein the conductive cladding forms recessed short circuit rings on the steel rod.

8 . The induction rotor of claim 7 , wherein the steel rod comprises longitudinally extending grooves formed along at least a portion of the surface.

9 . The induction rotor of claim 8 , wherein the conductive cladding forms an axial conductor by filling the grooves of the steel rod.

10 . The induction rotor of claim 7 , wherein the conductive cladding is comprised of at least one of a cylinder, a plurality of bars, or a powder.

11 . The induction rotor of claim 10 , wherein the conductive cladding is copper.

12 . The induction rotor of claim 10 , wherein the rotor includes an intermediate layer between the steel rod and the conductive cladding, the intermediate layer comprised of at least one of nickel or chromium.

13 . The induction rotor of claim 7 , wherein the rotor further comprises steel end rings positioned at opposite ends of the conductive cladding, the steel end rings increasing the structural integrity of the steel rod.

14 . A rotor comprising:
a steel rod having a surface, the surface including longitudinally extending grooves formed along at least a portion of the surface;
a conductive cladding comprising a clad material, the conductive cladding surrounding the grooves on the steel rod and the surface of the steel rod between the grooves;
end rings positioned at opposite ends of the conductive cladding and;
an axial conductor comprising a unitary layer formed by the clad material filling the grooves of the steel rod,
wherein the conductive cladding forms recessed short circuit rings on the steel rod.

15 . The induction rotor of claim 14 , wherein the steel rod further comprises shoulders.

16 . The induction rotor of claim 14 , wherein the conductive cladding is comprised of at least one of a cylinder, a plurality of bars, or a powder.

17 . The induction rotor of claim 16 , wherein the conductive cladding is copper.

18 . The induction rotor of claim 16 , wherein the rotor includes an intermediate layer between the steel rod and the conductive cladding.

19 . The induction rotor of claim 18 , wherein the intermediate layer is comprised of at least one of nickel or chromium.

Assignees

• Ingersoll Rand Industrial Us Inc

Inventors

• Boxberg Fredrik
• Saari Juha T
• Vikman Esa H M

Classifications

• B22F2301/35

  Iron · CPC title

• B22F2301/20

  Refractory metals · CPC title

• B22F2301/10

  Copper · CPC title

• B22F7/08

  with one or more parts not made from powder {(B22F7/062 takes precedence)} · CPC title

• B22F5/00

  Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product · CPC title