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Advanced Copper Joining Methods

Company: Wabtec

Major(s):
Primary: ME
Secondary: IE
Optional: ESC, MATSE

Non-Disclosure Agreement: YES

Intellectual Property: YES

Conduct a tradeoff study on Copper to Copper fusing techniques with a focus on optimizing for highest fatigue strength and highest electrical conductivity through the joint. Use an AC Motor “Rotor Bar to End Ring” design case as the baseline for this study. Evaluate traditional and non-traditional copper to copper joining methodologies (brazing, crimping, laser welding, electron beam welding, friction stir welding, etc). Within each potential methodology, determine the “best in class” process to optimize fatigue and electrical conductivity (example: brazing requires a braze alloy selection, flux selection and heat applicator… which is best)? Compare the best in class options within each methodology up to a top-level comparison between methodologies that will then define the “best in class” joining method. Define a Validation Plan that will prove out conclusions from the trade-off study. Stretch Goal: Identify vendors that can provide samples for each joining method. Provide a budgetary quote for sample parts from each vendor. Stretch Goal: Identify laboratory resource to conduct the validation plan. Provide a budgetary quote to complete the full scope of lab work.