Download the Complete Copper Electric Motor Component Case Study

The Problem:

Electric Motor Problem

When a leading manufacturer in the emerging market of electric vehicles required advanced electric motor prototype components, they needed a partner who could deliver the best results.  For example, they requested an 8-pound motor end cap which had to be manufactured in high-density copper with maximum durability and conductivity.

Though many suppliers and manufacturing processes were tested, only Queen City Forging provided the best option for combining the necessary dimensionality, metallurgy, cost efficiency, and production throughput.

First
First
Last
Last
Email Address
Email Address
Tell Us About Your Application

The Problem:

Electric Motor Problem

When a leading manufacturer in the emerging market of electric vehicles required advanced electric motor prototype components, they needed a partner who could deliver the best results.  For example, they requested an 8-pound motor end cap which had to be manufactured in high-density copper with maximum durability and conductivity.

Though many suppliers and manufacturing processes were tested, only Queen City Forging provided the best option for combining the necessary dimensionality, metallurgy, cost efficiency, and production throughput.

The Solution:

Electric Motor Solution

We overcame the challenge of converting pure copper, with its soft, diamagnetic properties, into a highly durable part. Our team of forging experts worked tirelessly to develop the following process, which proved to be the ideal solution:

  1. Heat the copper billet to high temperatures
  2. Place the billet on the forging die in a vertical orientation
  3. Allow deformation energy to create a fine, radial grain structure
  4. Conduct special thermal processing after the forging process
  5. Execute secondary operations to produce a net shape
  6. Finish with JIT delivery of the end cap to the automotive manufacture

The Results:

Electric Motor Results

Our unique expertise in copper forging and metallurgy allowed the development of an impression die process that delivered the perfect combination of production efficiency and end-use performance.

The finished product was:

  • A unique net shape part
  • Manufactured in high volume
  • Cost-competitive

Featured Application

video placeholder

Forging Innovations Blog

Forging Knowledge