Contacting of Copper-Clad Aluminum Hairpins for Electric Drives using Laser Welding

Wirthmann F, Baader M, Zürrlein T, Ihne T, Franke J, Risch F (2026)

Publication Language: English

Publication Type: Conference contribution, Conference Contribution

Publication year: 2026

Publisher: SINTEF Acadmeic Press

Series: SINTEF Proceedings

City/Town: Oslo, Norway

Pages Range: 187-196

Conference Proceedings Title: Proceedings of the 33rd International Conference on Electrical Contacts Trondheim, Norway, 21–25 June, 2026

Event location: Trondheim

ISBN: 978-82-536-1888-3

URI: https://nva.sikt.no/registration/019eb71ba6dd-06e6a2d3-4c78-4f94-9b1c-31936f99e179

Open Access Link: https://nva.sikt.no/registration/019eb71ba6dd-06e6a2d3-4c78-4f94-9b1c-31936f99e179

Abstract

The increasing demand for raw materials driven by industrial and societal electrification has intensified interest in alternative conductor materials for electric machines. Copper, while traditionally favored for its excellent electrical properties, poses economic and resource-based challenges due to rising prices and limited availability. Copper-clad aluminum (CCA) presents a promising alternative, combining the advantageous conductivity of copper with the low density and resource abundance of aluminum. This study investigates the applicability of CCA in hairpin winding technology for traction drives, focusing on the laser welding process as a viable contacting method. Key laser parameters - including power, feed rate, and beam path geometry - were varied systematically and evaluated with regard to weld seam morphology. Based on preliminary results, a full factorial design of experiments (DoE) was conducted for mechanical and electrical validation. The presented findings allow for a foundational understanding of CCA hairpin contacting and provide a basis for future optimization, such as detailed comparative studies with conventional copper and aluminum hairpins.

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How to cite

APA:

Wirthmann, F., Baader, M., Zürrlein, T., Ihne, T., Franke, J., & Risch, F. (2026). Contacting of Copper-Clad Aluminum Hairpins for Electric Drives using Laser Welding. In Magne Runde; Kaveh Niayesh, Åsa Kassman Rudolphi (Eds.), Proceedings of the 33rd International Conference on Electrical Contacts Trondheim, Norway, 21–25 June, 2026 (pp. 187-196). Trondheim, NO: Oslo, Norway: SINTEF Acadmeic Press.

MLA:

Wirthmann, Felix, et al. "Contacting of Copper-Clad Aluminum Hairpins for Electric Drives using Laser Welding." Proceedings of the 33rd International Conference on Electrical Contacts Trondheim, Trondheim Ed. Magne Runde; Kaveh Niayesh, Åsa Kassman Rudolphi, Oslo, Norway: SINTEF Acadmeic Press, 2026. 187-196.

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