Feasibility Study on Manufacturing Copper Windings by EBM

This study investigates the feasibility of using electron beam melting (EBM) to manufacture windings for electric motors from pure copper. A comprehensive parameter study is conducted to refine the process parameters which finally achieved over 99% of bulk density, 91.7±1.8 % of the electrical conductivity of standardized pure copper. Down-face sintering strategies are also employed to create sintered powder cake capable of supporting the overhangs. Additionally, the integration of cooling features into copper windings and the development of innovative continuous winding designs have been validated. This study demonstrates that EBM is a promising technique for manufacturing high-performance copper motor windings. Moreover, it effectively releases design limitations associated with copper motor windings, thereby enabling the integration of more advanced and functional design features.