About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Advanced Welding, Joining, and Bonding of Structural Steels
|
| Presentation Title |
Diffusion Bonding of Ultra-Conductive Composite to Busbar and Winding-Wire Conductors for Electric Vehicle Motor applications |
| Author(s) |
Hossein Abbasi, Lei Chen |
| On-Site Speaker (Planned) |
Hossein Abbasi |
| Abstract Scope |
The growth of electric vehicles has increased the demand for motor conductors with high electrical and thermal conductivity, low current-distribution losses, and reliable mechanical integrity. This study investigates diffusion bonding of an ultra-conductive composite (UCC) to busbar and winding-wire conductors for EV motor applications. The approach forms a continuous conductive surface layer intended to improve surface current transport and reduce skin-effect-related current concentration during high-frequency operation. Bonding temperature, holding time, pressure, and surface preparation were evaluated using a custom graphite clamping system for controlled pressure application. Results show that suitable temperature and bonding time promoted interfacial diffusion and uniform bonding, while improved surface preparation and lower pressure reduced voids, excessive interfacial reaction, and conductor deformation. Reducing pressure from 26 MPa to 13 MPa decreased thickness change from 0.130 mm to 0.044 mm. These results demonstrate diffusion bonding as a scalable route for integrating UCC layers with EV motor conductors. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Joining, Copper / Nickel / Cobalt, Thin Films and Interfaces |