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Joining of the Laminated Electrical Steels in Motor Manufacturing: A Review
Article in Materials · October 2020

DOI: 10.3390/ma13204583
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materials
Review
Joining of the Laminated Electrical Steels in Motor
Manufacturing: A Review
Cunjuan Xia, Hongze Wang * , Yi Wu and Haowei Wang
State Key Laboratory of Metal Matrix Composites, School of Materials Science & Engineering, Shanghai Jiao
Tong University, No. 800 Dongchuan Road, Shanghai 200240, China; xiacunjuan@sjtu.edu.cn (C.X.);
eagle51@sjtu.edu.cn (Y.W.); hwwang@sjtu.edu.cn (H.W.)
* Correspondence: hz.wang@sjtu.edu.cn

Received: 3 September 2020; Accepted: 13 October 2020; Published: 15 October 2020
Abstract: In recent years, the motor has been increasingly used to replace the conventional gasoline
engine for carbon emission reduction, and the high-performance motor is urgently required. The stator
and rotor in a motor are made of hundreds of joined and laminated electrical steels. This paper covers
the current research in joining the laminated electrical steels for the motor application, together with
the critical assessment of our understanding. It includes the representative joining method, modeling
of the joining process, microstructure of the weld zone, mechanical strength and magnetic properties.
The gaps in the scientific understanding, and the research needs for the expansion of joining laminated
electrical steels, are provided.
Keywords: electrical steel; joining and welding; microstructure; magnetic property;

mechanical property
1. Introduction
As a machine to transform the electrical energy into mechanical energy, a motor has been widely
used as the traction machine in industry equipment [1–7], e.g., electrical vehicle, electrical airplane,
electric ship, and so on. Electrical steel [8–11], a high silicon (2–5.5 wt% Si) [12,13] and thin sheet
(0.2–0.65 mm) steel [14], is the soft magnetic material for the stator and rotor in a motor [15–17].
The addition of silicon to iron results in a decrease in coercivity and an increase in resistivity [12,18–22].
Furthermore, the reduction of the sheet thickness results in the reduction of the eddy current loss
in the electrical steel when put in the alternating magnetic field environment [14,23,24]. The stator
and rotor in a motor are made of hundreds of laminated and joined thin electrical steel sheets [25],
which could reduce the eddy current loss and improve efficiency. There are insulation coatings on both
sides of the electrical steel sheet to cut off the interlaminar eddy current when hundreds of electrical
steels are laminated in the motor application [26–36]. Generally, the goal of joining the laminated
electrical steels is to ensure the mechanical strength of the laminations [37], while the joining process
will lead to the degradation of the magnetic properties due to the damage of the insulation coating [38],
the modification of the microstructure [39,40], the introduction of the residual stress [41], and so on.
It is a great challenge to reach the trade-off between mechanical strength and magnetic properties [42].
Besides, the structure of the laminated electrical steels is different from the conventional lapped or
butted sample, and the conventional knowledge about joining may not work for joining the laminations.
Finally, it is important to study the joining of the laminated electrical steels, which could speed up the
roadmap towards high-quality motor manufacturing.
Figure 1 shows the number of papers in the Scopus database about the joining and welding of
laminated electrical steels. As shown, it is an emerging research topic with rapidly increasing speed in
the last decade. There is no doubt that more research about this topic will appear along with the rapid
Materials 2020, 13, 4583; doi:10.3390/ma13204583 www.mdpi.com/journal/materials

Materials 2020, 13, 4583 2 of 21
Materials 2020, 13, x FOR PEER REVIEW 2 of 23
increase
rapid of the electric
increase vehicle vehicle
of the electric market. market.
In this manuscript, the current
In this manuscript, theprogress
current in joining in
progress thejoining
laminated
the
electrical steels
laminated is summarized,
electrical the gaps in the scientific
steels is summarized, understanding
gaps in the and the research
scientific understanding and needs in this
the research
field are
needs in provided based
this field are on the authors’
provided based onresearch experiences.
the authors’ research experiences.
Figure 1.
Figure The number
1. The number ofof papers
papers in
in Scopus
Scopus varying
varying with
with the
the year
year when
when searching
searching with
with the
the combined
combined
keywords of “electrical steel” and “welding” or “joining” in the title, abstract and keywords.
keywords of “electrical steel” and “welding” or “joining” in the title, abstract and keywords.
2. The Representative Joining Method
2. The Representative Joining Method
Currently, the joining method for the laminated electrical steels could be generally categorized into
Currently, the joining method for the laminated electrical steels could be generally categorized
three types: glue join [26,43], mechanical join [44] and fusion welding [45], as shown in Figure 2 [40].
into three types: glue join [26,43], mechanical join [44] and fusion welding [45], as shown in Figure 2
The advantage of the glue-join method was that it did not destroy the insulation coating. Kaido et al. [26]
[40]. The advantage of the glue-join method was that it did not destroy the insulation coating. Kaido
measured the magnetic and mechanical characteristics of adhesive coating non-oriented electrical steel
et al. [26] measured the magnetic and mechanical characteristics of adhesive coating non-oriented
sheet cores in the conditions of motor and found that the deteriorations of iron losses and exciting
electrical steel sheet cores in the conditions of motor and found that the deteriorations of iron losses
currents by adhesion were less than those by welding. Schoppa et al. [46] coated the electrical steel
and exciting currents by adhesion were less than those by welding. Schoppa et al. [46] coated the
laminations with the adhesive varnish, then the laminations were stuck together during a thermally
electrical steel laminations with the adhesive varnish, then the laminations were stuck together
activated process. Their experimental results showed that the increase of the specific core loss after
during a thermally activated process. Their experimental results showed that the increase of the
sticking was very low, and they concluded that sticking was from the magnetic point of view one of
specific core loss after sticking was very low, and they concluded that sticking was from the magnetic
the best methods of assembling laminations into magnetic cores. The glue-join method also allowed
point of view one of the best methods of assembling laminations into magnetic cores. The glue-join
homogenous electrical isolation, reduced acoustic emission, and behaved high thermal conductivity
method also allowed homogenous electrical isolation, reduced acoustic emission, and behaved high
in service [26,43]. Generally, the composition of the glue varies with the supplier, including the
thermal conductivity in service [26,43]. Generally, the composition of the glue varies with the supplier,
organic glue, inorganic glue and their combinations. However, the biggest obstacle for the large-scale
including the organic glue, inorganic glue and their combinations. However, the biggest obstacle for
application of this technique was the concern about the mechanical failure of the adhesion under the
the large-scale application of this technique was the concern about the mechanical failure of the
periodic load condition at an elevated temperature during the operation of the motor [47]. Besides,
adhesion under the periodic load condition at an elevated temperature during the operation of the
the cost was also higher than the other joining methods [46].
motor [47]. Besides, the cost was also higher than the other joining methods [46].
Both mechanical joining [44,48–50] and fusion welding [37,38,46,51,52] are widely used to join the
Both mechanical joining [44,48–50] and fusion welding [37,38,46,51,52] are widely used to join
laminated electrical steels at present. Senda et al. [44] compared the effects of two representative V-type
the laminated electrical steels at present. Senda et al. [44] compared the effects of two representative
mechanical interlocking methods, dowel formation and dowel jointing on the magnetic properties
V-type mechanical interlocking methods, dowel formation and dowel jointing on the magnetic
of the joined ring core sample made of the electrical steel laminations, they found that two methods
properties of the joined ring core sample made of the electrical steel laminations, they found that two
showed comparable contributions to iron loss increase at low frequencies (e.g., 50 Hz), whereas,
methods showed comparable contributions to iron loss increase at low frequencies (e.g., 50Hz),
increases in iron loss due to dowel jointing were greater than those due to dowel formation at high
whereas, increases in iron loss due to dowel jointing were greater than those due to dowel formation
frequencies. Imamori et al. [49] investigated the influence of interlocking on the magnetic properties of
at high frequencies. Imamori et al. [49] investigated the influence of interlocking on the magnetic
ring cores by measurement, and they observed that the inverse of permeability and iron loss increased
properties of ring cores by measurement, and they observed that the inverse of permeability and iron
linearly with the number of interlocks. The mechanical joining process is usually combined with the
loss increased linearly with the number of interlocks. The mechanical joining process is usually
punching process in the progressive stamping die process. Finally, the cost of the mechanical joining
combined with the punching process in the progressive stamping die process. Finally, the cost of the
process is a bit lower than that of the welding process. The disadvantage of the mechanical joining
mechanical joining process is a bit lower than that of the welding process. The disadvantage of the
mechanical joining method is the lower strength at the direction perpendicular to the electrical steel
Materials 2020, 13, 4583 3 of 21
surface
methodcompared
is the lower to that of theatfusion
strength welded perpendicular
the direction joint. Besides, the mechanically
to the joined
electrical steel joint compared
surface has a lowerto
fatigue
that of life under the
the fusion periodic
welded joint.loads thanthe
Besides, that of the welded
mechanically joint.
joined In has
joint the acase
lowerwith the high
fatigue strength
life under the
requirement, several fusion welding passes were jointly used to enhance
periodic loads than that of the welded joint. In the case with the high strength requirement, several the strength of the
mechanically
fusion welding joined
passessample.
were jointly used to enhance the strength of the mechanically joined sample.
The
Theheatheatsource
sourceusedusedin infusion
fusionwelding
weldingofofthe theelectrical
electricalsteel
steellaminations
laminationsincludes
includeslaser laser[37],
[37],
electron
electronbeams
beams[53],[53],plasma
plasmaarcs arcs[39],
[39],electric
electricarcs
arcs(TIG,
(TIG,GTA,
GTA, CMT) CMT) [51,54],
[51,54], and
and so so on.
on. As Asaahigh
high
efficiency
efficiency and high-quality
high-qualityfusion fusionwelding
welding method,
method, laser
laser welding
welding was was
thoughtthought
to be atopotential
be a potential
method
method for welding
for welding of thesteel
of the electrical electrical steel laminations
laminations in the high-performance
in the high-performance motor application motor application
[37,40,42,51,55].
[37,40,42,51,55].
Compared to the Compared
other fusion to welding
the othermethods,
fusion welding methods,
laser welding couldlaser welding
achieve could
a smaller achieve
heat a
affected
smaller heat affected
zone, induce lower zone,
residual induce
stress,lower
andresidual stress, and
finally obtain finally obtain
the welded the welded
electrical electrical steel
steel laminations with
laminations
higher magnetic withproperties.
higher magnetic Figure 3properties. Figure 3 shows
shows the schematic of laserthe schematic
welding of laserelectrical
of laminated weldingsteelof
laminated
laminations electrical
[40]. Thesteel laminations
moving energy [40].
beamThemelt
moving energy
the edge ofbeam melt the edge
the laminations of the laminations
continuously and the
continuously
effective jointand wasthe effective
formed at thejoint was formed
interfaces of theatlaminations.
the interfaces of the laminations.
Table
Table11shows
showsthe therepresentative
representativeresearchresearchin inthe
thejoining
joiningofoflaminated
laminatedelectrical
electricalsteels.
steels.TheThecritical
critical
factors
factors affecting joining
joiningthe thelaminated
laminated electrical
electrical steelsteel laminations
laminations are asare as follows:
follows: (a) thestructure
(a) the special special
structure of the laminations
of the laminations made ofmade hundredsof hundreds of electrical
of electrical steel sheets;
steel sheets; (b) the(b)insulation
the insulation
coating coating
on bothon
both
sidessides
of theof the electrical
electrical steelsteel sheet,
sheet, which
which affects
affects thethedynamics
dynamicsofofthe themolten
molten pool during
during the thefusion
fusion
welding
weldingprocess
processbecause
becauseof ofthe
theentrapped
entrappedbubbles
bubblesdue dueto tothe
thepyrolysis
pyrolysisof ofthe
thecoating
coatingand andmay mayinduce
induce
pores
poresininthetheweld
weldseam;
seam;(c) (c)thethecomprehensive
comprehensiverequirement
requirementofofthe thestrength
strengthand andmagnetic
magneticproperty.
property.
The
Thefollowing
followingsections
sectionswill willsummarize
summarizethe thecurrent
currentresearch
researchininjoining
joiningofoflaminated
laminatedelectrical
electricalsteels,
steels,
which provides a better understanding of the joining process with great
which provides a better understanding of the joining process with great demands from the industry. demands from the industry.
Figure 2. Schematic of the representative join methods for laminated electrical steels: (a) Glue join;
Figure 2. Schematic of the representative join methods for laminated electrical steels: (a) Glue join; (b)
(b) mechanical join; (c) fusion welding [40].
mechanical join; (c) fusion welding [40].
Materials 13, 4583
2020,2020,
Materials 13, x FOR PEER REVIEW 4 of 23 4 of 21
Figure 3. Schematic of the fusion welding process [40].

Figure 3. Schematic of the fusion welding process [40].
Table 1. Representative research in the joining of laminated electrical steels.
Joining Method Research Content Year Reference

Strength: both the strength and the fatigue
behavior of the weld material showed no
appreciable difference to the base material;
Continuous laser welding 2014 [37]
Microstructure: completely ferritic in both
the base material and the weld seam;
Defect: pores observed in the weld seam
Model for torsion strength: mathematical
model with the function to estimate the
strength of the welded laminations based
on the welding parameters
Strength of the welded ring stator: increase
with the heat input; Microstructure ferrite
in the weld seam; Magnetic property:
deteriorate with the heat input
Simulation of temperature distribution:
discontinuous temperature distribution in
the heat affected zone due to the hinder of
the interface
Strength, microstructure, magnetic
property: TIG welded joint has higher
Continuous TIG welding 2017 [51]
strength, coarser grain and worse magnetic
property than laser welded joint
Magnetic property: mathematical model
Continuous welding and FEM model were developed to 2017 [57]
estimate the eddy current loss
Interlaminar eddy currents mainly affect
Mechanical joining 2017 [49]
the iron loss of the local zone.
Mechanical property: critical adhesive
shear angle values of about 5◦ were
Glue obtained for all laminate samples, 2018 [26]
independent of the steel substrates used to
create the laminates
Possibility of the adaptive pulsed spot
Adaptive pulsed spot welding welding for laminated electrical steels 2014 [55]
was proved.
The strategy of distributed welding spot
Statistical distribution of single shows promising results to decrease the
2018 [42]
welding spots magnetic deterioration, especially as an
approach for higher frequency applications
Materials 2020, 13, 4583 5 of 21
3. Characteristics of the Joined Zone

As high silicon (2–5.5 wt% Si) [12,13] and low carbon steel, the basic ferric phase appears in
the base material of the electrical steel. Wang et al. [40] investigated the surface morphology and
microstructure of the laser-welded electrical steel laminations joint. As shown in Figure 4, the surface
of the weld seam has a good quality and there is no obvious defect there. Because of the high content of
the silicon element, the weld seam zone is still made of the ferric phase even if it solidifies with a high
cooling rate. Epitaxial growth based on the grains at the base metal happens, and columnar grains
growing towards the direction of the temperature gradient appears in the weld seam zone. Small pore
defects are observed in the zone near the boundary of the weld seam [40]. This research provides an
insight into the microstructures at both the surface and the interior of the laser welded electrical steel
joint. Senda et al. [44] investigated the characteristics and hardness distribution of the mechanically
interlocked joint. As shown in Figure 5, the large local deformation at the edge of the dowel led to the
interlock between the laminations, and hardness of the edge zone increased due to the strengthening
effect. This research provides a clear insight into the shape and hardness of the mechanical interlocked
joint. However, current research about the characteristics of the joined zone of the electrical steel
laminations is still limited, much work is required to clarify the processing parameter window for
defect-free
Materials 2020, 13,joint,
x FORthe grain
PEER size and orientation, and so on.
REVIEW 7 of 23
Figure 4. Characteristics of the weld seam in laser-welded laminated electrical steels made with a
welding speed of 10 mm/s: (a) Overall view; (b) upper surface; (c) longitudinal section; (d) cross
section [40].
section [40].
Materials 2020, 13, 4583 6 of 21
section [40].
Figure 5.
Figure Cross-sectional view
5. Cross-sectional view and
and hardness
hardness distribution
distribution of
of the
the mechanical
mechanical interlock
interlock joint:
joint: (a)
(a) Along
Along
the short
the short edge
edge direction;
direction; (b)
(b) along
along the
the long
long edge
edge direction
direction [44]. The microhardness
[44]. The microhardness was
was measured
measured
every 0.1 mm.
every 0.1 mm.
4. Simulation of the Joining Process
4. Simulation of the Joining Process
The simulation will act as a useful tool to reveal the mechanism underlying the process of joining
The simulation will act as a useful tool to reveal the mechanism underlying the process of joining
the laminated electrical steels. Though this method has been widely used in the field of joining
the laminated electrical steels. Though this method has been widely used in the field of joining and
and welding of various materials [58,59], the research about the simulation of joining the laminated
welding of various materials [58,59], the research about the simulation of joining the laminated
electrical steels is still at the initial stage [47]. One of the difficulties in the simulation of welding the
electrical steels is still at the initial stage [47]. One of the difficulties in the simulation of welding the
laminated electrical steels is how to describe the effect of the interfaces on the heat transfer during
laminated electrical steels is how to describe the effect of the interfaces on the heat transfer during
the welding process. Wang et al. [47] developed a thermal analysis finite element model in ANSYS to
the welding process. Wang et al. [47] developed a thermal analysis finite element model in ANSYS
calculate the temperature distribution and analyze the evolution of the interfaces during laser welding
to calculate the temperature distribution and analyze the evolution of the interfaces during laser
of the laminated electrical steel laminations, as shown in Figure 6. In the model, the technique of
welding
Materialsof the
2020, 13, laminated electrical steel laminations, as shown in Figure 6. In the model,
x FOR PEER REVIEW the
8 of 23
“birth” and “death” element was used to describe the effects of the interfaces on the heat transfer,
technique of “birth” and “death” element was used to describe the effects of the interfaces on the heat
where two the
describe groups of values for theofthermal contact conductance were used respectively to describe
transfer, whereheat twotransfer
groups ability
of valuesthe
forinterface before
the thermal and after
contact melting.
conductance Based on this
were used model, the to
respectively
thesimulated
heat transfer ability of the interface before and after melting. Based on this model, the
molten pool fit well with the experimental one. In the future, much work should be done simulated
molten pool fitthe
to analyze well with
flows ofthe
theexperimental one.
material at the In the future,
interface, much work
the evolution should
of the be doneand
temperature to analyze
residualthe
flows of the
stress, andmaterial
so on. at the interface, the evolution of the temperature and residual stress, and so on.
Figure
Figure (a)(a)Schematic
6. 6. Schematicofofthe theheat
heattransfer
transfer process at the
the longitudinal
longitudinalsection
sectionofofthe
theweld
weld seam
seam during
during
thethe welding
welding process;(b)
process; (b)simulated
simulatednon-uniform
non-uniform temperature
temperature distribution
distributionatatthe
thelongitudinal
longitudinalsection
section
of of
thethe weld
weld seambecause
seam becauseofofthe thehindrance
hindrance of
of the
the interface
interface on
on heat
heattransfer;
transfer;(c) (c)simulated
simulateduniform
uniform
temperature distribution at the longitudinal section of the weld seam when the
temperature distribution at the longitudinal section the weld seam when the interface was melted interface was melted
duedue
to to absorbing
absorbing theenergy
the energyofoflaser
laser[47].
[47].
5. Mechanical Properties
The greatest challenge in joining the laminated electrical steels is to achieve excellent mechanical
properties and magnetic properties at the same time. Though the stator and rotor in a motor do not
have high requirements for the joint strength between the laminations, it is still important to evaluate
the shear strength and the fracture shear strain of the joint. Figure 7 shows the schematics for
Materials 2020, 13, 4583 7 of 21
5. Mechanical Properties
The greatest challenge in joining the laminated electrical steels is to achieve excellent mechanical
properties and magnetic properties at the same time. Though the stator and rotor in a motor do not
have high requirements for the joint strength between the laminations, it is still important to evaluate
the shear strength and the fracture shear strain of the joint. Figure 7 shows the schematics for measuring
the shear strength of the bonded laminations and the fracture strain. In the sample preparation stage,
the adhesive was first applied to square steel sheets using a doctor knife and was pre-crosslinked to a
non-sticky stage, then the steel sheets with pre-cured adhesive were stacked to form a 6-layer laminate
and cured at 160 ◦ C for 90 min [26]. The three-point bending experiment was used to measure the
shear strength of the bonded laminations, and the shear fracture strain could be measured by the
digital image correlation method [26]. This is a useful method to evaluate the mechanical properties of
the bonded laminations, while may not work well for the mechanically interlocked or fusion-welded
ones due
Materials to 13,
2020, thex small joining
FOR PEER area in these two methods.
REVIEW 9 of 23
Schematic illustration
Figure 7. Schematic illustration of
of surface
surface discretization
discretization by
by facets
facets required
required for full-field
full-field strain analysis
at an initial stage and an idealized deformed stage, before (left) and after (right) ultimate failure, the
schematic illustration
schematic illustration of
of dynamic
dynamic mechanical
mechanical analysis
analysis setup
setup in
in the
the three-point
three-point bending
bending mode
mode with
with
relevant support distance was also laid out at the left corner [26]. In this literature, the adhesive was
relevant support distance was also laid out at the left corner [26]. In this literature, the adhesive was
first applied
first applied toto square
square steel
steel sheets
sheets using
using aa doctor
doctor knife
knife and
and was
was pre-crosslinked
pre-crosslinked toto aa non-sticky
non-sticky stage,
stage,
then the
then the steel sheets with
steel sheets with pre-cured
pre-cured adhesive were stacked
adhesive were stacked to
to form
form aa 6-layer laminate and
6-layer laminate and cured
cured at
at
160 ◦ C for
for 90
90 min.
min.
160 °C
To measure
To measurethe thetorsion
torsion strength
strength of fusion-welded
of the the fusion-welded ring electrical
ring electrical steel laminations,
steel laminations, Wang et
Wang et al. [40] developed a three-jaw chuck adaptor, which was assembled
al. [40] developed a three-jaw chuck adaptor, which was assembled with a torsion testing with a torsion testing
machine,
machine, as shown in Figure 8. This system was successfully used to measure
as shown in Figure 8. This system was successfully used to measure the torsion-property of the laserthe torsion-property
of the laser
welded ringwelded
sample,ring
andsample,
could alsoandbecould also betoexpanded
expanded measure theto measure the torsion
torsion property property
of the of the
ring sample
ring sample joined by mechanical interlock and glue, as well as the joined stator and
joined by mechanical interlock and glue, as well as the joined stator and rotor in an actual motor. In rotor in an actual
motor.
the In the
actual actual application,
application, the rectangular
the rectangular electrical
electrical steel steel laminations
laminations sample hassample has been
been widely usedwidely
at the
used at
stage of the stage the
hunting of hunting the parameter
processing processingwindow.
parameter Towindow.
measureTo themeasure the shear
shear strength of strength
the weldof the
seam
weld seam in the rectangular sample, Zhang et al. [51] designed a special structure,
in the rectangular sample, Zhang et al. [51] designed a special structure, where two weld seams were where two weld
seams were symmetrically
symmetrically distributed distributed
at each edge at each edge
of the of theas
sample, sample,
shownasinshownFigurein 9.
Figure
These9. systems
These systems
act as
useful tools to evaluate the strength of the joined laminations with different geometric shapes.shapes.
act as useful tools to evaluate the strength of the joined laminations with different geometric In the
In the future,
future, the digital
the digital imageimage correlation
correlation methodmethod
couldcould also
also be be used
used to measure
to measure the local
the local strain
strain during
during the
the loading
loading process. process.
Materials 2020,
Materials 2020, 13,
13, 4583
x FOR PEER REVIEW 108 of 23
of 21
Figure 8. (a) Experimental system to measure the torsion properties of the fusion-welded laminations;
Figure (a) Experimental
8. (a) Experimental
(b) experimental system to
system
torsion properties toof
measure
measure the torsion
the torsionlaminations;
the laser-welded properties of
properties of(c)
the
the fusion-welded
fusion-welded
characteristics laminations;
oflaminations;
the fracture
(b) experimental
(this subfigure is torsion
reeditedproperties of the
based on the laser-welded
original image). laminations; (c) characteristics
The fracture appeared of the
at the weld fracture
zone along
(this subfigure is reedited
reedited based
based on
on the original image).
image). The fracture appeared at the weld
with the interface of the welded laminations and the fracture mode belonged to the interfacial fracture, zone along
with
with the
the interface
interface
characteristics of
of the
of the the welded
welded
fracture laminations
laminations
showed and
and the
that brittle the fracture
fracture
fracture mode
mode belonged
happened belonged to
to the
at the interfacethe interfacial
interfacial
on fracture,
fracture,
the torsion load
characteristics
characteristics of the fracture showed that brittle fracture happened at the interface on the
condition [40].of the fracture showed that brittle fracture happened at the interface on the torsion load torsion load
condition
condition [40].
[40].
Figure 9. Schematic of the specimen to evaluate the lap strength of the fusion-welded laminated
Figure 9. Schematic of the specimen to evaluate the lap strength of the fusion-welded laminated
electrical steels [51]. Weld seams were set symmetrically at two sides of the specimen to keep the
Figure 9. steels
electrical Schematic
[51]. of the seams
Weld specimen
weretoset
evaluate the lap strength
symmetrically of the
at two sides fusion-welded
of the specimen tolaminated
keep the
balance during the lap shear process.
electrical steels the
balance during [51].lap
Weld
shearseams were set symmetrically at two sides of the specimen to keep the
process.
balance
6. System toduring
Measurethe lap
theshear process.
Magnetic Properties
6. System to Measure the Magnetic Properties
Magnetic
6. System properties
to Measure theare the other
Magnetic indicators to evaluate the performance of the welded electrical
Properties
steel laminations except for the torsionindicators
Magnetic properties are the other to evaluate
strength. Wang et al. the
[40]performance of the weldedsystem
adopted an experimental electrical
to
Magnetic
steel laminations
measure properties are the
exceptproperties
the magnetic other
for the torsion indicators
of thestrength. to
welded Wangevaluate
et al.
electrical the performance
[40]laminations,
steel of the welded
adopted an experimental electrical
system10.
as shown in Figure to
steel laminations
measure
The except
the magnetic
measurement for of
thethe
properties
principle torsion
of thestrength.
system was as Wang
welded et[40]:
electrical
follows al. [40]laminations,
steel adopted an experimental system10.
as shown in Figure to
measure the magnetic
The measurement properties
principle of the of the welded
system was as electrical steel laminations, as shown in Figure 10.
follows [40]:
The measurement principle of the system was as follows [40]:
(1) The iron loss of the welded laminations could be calculated by Equation (1):
Materials 2020, 13, 4583 9 of 21
Materials 2020, 13, x FOR PEER REVIEW Z 11 of 23
1 dB
Ps = H dt (1)
ρ1 T dt
1 t dB
 H dt dt
Ps = (1)
where ρ1 was the density of the electrical steelρsample,
1T t T was the period of time in the measurement.
where (2)𝜌The magnetic
was fieldof
the density Hthe
waselectrical
calculated bysample,
steel Equation (2): the period of time in the measurement.
T was
(2) The magnetic field H was calculated by Equation N I (2):
H= 11 (2)
NLI
H = 11 (2)
L
where N1 was the primary winding turns, I1 was the current in the primary winding, and L was the
where
length N wasequivalent
of1 the the primary winding
magnetic turns,which
circuit, I1 wascould
the current in the primary
be calculated winding,
by Equation (3): and L was the
length of the equivalent magnetic circuit, which could be calculated by Equation (3):
L = π(D1 + D2 )/2 (3)
L = π ( D1 + D2 ) 2 (3)
where D1 was the external diameter of the ring laminations, and D2 was the internal diameter of the
where D1 was the external diameter of the ring laminations, and D2 was the internal diameter of the
ring laminations.
ring laminations.
(3) the magnetic flux density through the laminations was calculated by Equation (4):
(3) the magnetic flux density through the laminations was calculated by Equation (4):
Z
1
B=− 1
N2S 
B = − N2 S UU22dt dt (4)
(4)
where N2 was the secondary winding turns, U2 was the voltage between the secondary winding, and S
where N2 was the secondary winding turns, U2 was the voltage between the secondary winding, and
was the section area of the secondary winding, which could be calculated by Equation (5):
S was the section area of the secondary winding, which could be calculated by Equation (5):
S= h 1( D
S h=(D −1D−2D2) 2
)/2 (5)
(5)
where
where hh was
was thethe height
height of
of the
the ring laminations.
ring laminations.
Before
Before thetheexperiment,
experiment, thethe
welded sample
welded was winded,
sample and the
was winded, numbers
and of the primary
the numbers of the winding
primary
turns and the secondary winding turns were counted, respectively. The other papers also
winding turns and the secondary winding turns were counted, respectively. The other papers also mentioned
similar experimental
mentioned systems to measure
similar experimental systems the magneticthe
to measure properties
magneticofproperties
the electrical steel
of the laminations
electrical steel
[48,60,61], and all these systems were developed based on the same principle.
laminations [48,60,61], and all these systems were developed based on the same principle.
Figure 10.
Figure System to
10. System tomeasure
measure the
the magnetic
magnetic properties:
properties: (a)
(a) The
The schematic;
schematic; (b)
(b) the
thewinded
windedsample
sample[40].
[40].
II11was
wasthe
thecurrent
currentin
inthe
theprimary
primarywinding,
winding,I(t)
I(t)represented
represented the
themodule
module generating
generating thethe current
current varying
varying
with the
with thetime,
time,R Rrepresented
representedthethe
resistance module,
resistance U2 was
module, U2the voltage
was betweenbetween
the voltage the secondary winding,
the secondary
winding, A represented the analog signal processing module, D represented the digitalmodule,
A represented the analog signal processing module, D represented the digital signal processing signal
and PC represented
processing the personal
module, and computer.
PC represented the personal computer.
7. Eddy Current Loss Increase Induced by the Joining Process

The mechanical interlock and the fusion welding lead to the connection of the electrical steel
laminations, which will increase the eddy current loss. Lamprecht et al. [62] developed a finite
element model to identify the eddy current characteristics within the laminated stack and calculate
the losses in the mechanically interlocked stack, the results showed that the eddy current losses
increased for the interlocked sample in comparison to a perfectly insulated reference sample (Figure
11a,b). They also addressed the combination of the stacking impact and an additional electrical
Materials 2020, 13, 4583 10 of 21
7. Eddy Current Loss Increase Induced by the Joining Process

The mechanical interlock and the fusion welding lead to the connection of the electrical steel
laminations, which will increase the eddy current loss. Lamprecht et al. [62] developed a finite element
model to identify the eddy current characteristics within the laminated stack and calculate the losses
in the mechanically interlocked stack, the results showed that the eddy current losses increased
for the 2020,
Materials interlocked
13, x FOR sample in comparison to a perfectly insulated reference sample (Figure 12
PEER REVIEW 11a,b).
of 23
They also addressed the combination of the stacking impact and an additional electrical connection
connection of the laminations
of the laminations as it may occuras it when
may occur whencores
the stator the stator cores were
were pressed intopressed into an conductive
an electrically electrically
conductive
housing (Figure housing (Figure
11c,d). Wang 11c,d).
et al.Wang et al. [57] adeveloped
[57] developed mathematical a mathematical
model based model
on thebased on the
equivalent
equivalent
circuit method circuit
to method
calculatetothe calculate the eddy
eddy current current
loss in theloss in theelectrical
welded welded electrical steel laminations,
steel laminations, and the
and
finitethe finite element
element model was modelalsowas also
built tobuilt to estimate
estimate the eddy thecurrent
eddy current distribution
distribution in the in theweld
local local zone,
weld
zone,
as shownas shown in Figure
in Figure 12. The12.estimated
The estimatededdyeddy current
current loss byloss
thebymathematical
the mathematical
model model fit well
fit well withwith
that
that
by thebyfinite
the finite element
element model,model,
thus, thus, the mathematical
the mathematical modelmodel
couldcould estimate
estimate the current
the eddy eddy current
loss ofloss
the
of the welded
welded laminationslaminations in the
in the actual actual
motor withmotor with high efficiency,
high calculation calculation efficiency,
while the finitewhile
elementthemodel
finite
element modelthe
could estimate could
localestimate the local
distribution of thedistribution
eddy current of loss
the eddy
in the current
weld seamlosszone
in the weld
with highseam zone
accuracy.
with high
Finally, accuracy.
both Finally, both
the mathematical the mathematical
model and the finitemodel
element andmodel
the finite element
could behavemodel could behave
as a useful tool to
as a useful
estimate tool
the to estimate
eddy current the eddy
losses in current losses
the welded in the welded
electrical electrical steel
steel laminations, laminations,
towards towards
high magnetic
high magnetic
property weldingproperty
of the welding of the laminations.
laminations.
11. Cross-section
Figure 11.
Figure Cross-sectionview viewof:of:
(a,b) interlocked
(a,b), electrical
interlocked steel laminations;
electrical (c,d) with
steel laminations; (c,d)nickel
withcoating
nickel
at the edge. (a,c) entire cross section. (b) interlock area detail of (a); (d) interlocking/nickel coating
coating at the edge. (a,c), entire cross section. (b), interlock area detail of (a); (d), interlocking/nickel area
detail ofarea
coating (c) [62]. Theofarrows
detail represent
(c) [62]. The arrowsthe eddy current
represent thedensity and direction,
eddy current densityfive
andlaminations, 400
direction, five
Hz/1.0 T. The400
laminations, length scales
Hz/1.0 T. have been added
The length scales to the been
have figureadded
and the
to font size ofand
the figure the eddy current
the font scales
size of the
have been enlarged to make them more visable.
eddy current scales have been enlarged to make them more visable.
Materials 2020, 13, 4583 11 of 21
Figure 12. (a) Schematic of the welded electrical steel laminations; (b) schematic of the eddy current
Figure 12. (a) Schematic of the welded electrical steel laminations; (b) schematic of the eddy current
distribution at the cross section of the welded laminations under alternative magnetic field environment;
distribution at the cross section of the welded laminations under alternative magnetic field
(c) simulated eddy current loss distribution at the cross section of the laminations without welding;
environment; (c) simulated eddy current loss distribution at the cross section of the laminations
(d) simulated eddy current loss distribution at the cross section of the welded laminations through the
without welding; (d) simulated eddy current loss distribution at the cross section of the welded
weld seam [57].
laminations through the weld seam [57].
8. Stress Induced Magnetic Properties Degradation
8. Stress Induced Magnetic Properties Degradation
Manufacturing process, e.g., punching or cutting [63–65], welding [46], pressing and
Manufacturing
shrink-fitting process, residual
[66] produced e.g., punching
stress, or cutting
which was[63–65], weldingto[46],
also reported leadpressing and shrink-
to the degradation
fitting [66] produced residual stress, which was also reported to
of the magnetic properties [67–77]. Karthaus et al. [78] developed an approach for modeling lead to the degradation of the
magnetic properties
stress-dependent [67–77].
magnetic Karthaus
material et al. [78]
properties suchdeveloped
as magnetic an flux
approach
densityfor modeling
using stress-
a continuous
dependent magnetic material properties such as magnetic flux density
local material model, and the presented model allowed a simple determination of model parameters using a continuous local
material model, and the presented model allowed a simple determination
by using stress-dependent magnetic material measurements, as shown in Figure 13a. The results of the of model parameters by
using stress-dependent
mechanical stress-dependentmagnetic material
hysteresis measurements,
curves as shown
for tensile stress for 50inHz Figure
were13a. The in
shown results
Figureof13b.
the
mechanical stress-dependent hysteresis curves for tensile stress for 50 Hz
It can be observed that tensile stress caused a shear of the hysteresis curves. Thus, the magnetic were shown in Figure 13b.
It can be observed
properties that tensile
such as magnetic stress caused
remanence or irona shear
lossesofwere
the hysteresis
altered bycurves. Thus, thestress
the mechanical magnetic
[78].
properties such as magnetic remanence or iron losses were altered by the
The following model could describe the magnetic flux density degradation because of the motivation mechanical stress [78]. The
following model could describe the magnetic flux density degradation because
of the mechanical stress [78], B(σ, H ) = µ0 H [µr (σ = 0, H ) − ∆µσ (H )G(σ)], where H was the strength of the motivation of
thethe
of mechanical
magneticstress σ was𝐵the
field, [78], 𝜎, 𝐻 𝜇 𝐻 𝜇mechanical
impressed 𝜎 0, 𝐻 stress, ∆𝜇 µ 𝐻0 𝐺
was𝜎 the, where
magnetic 𝐻 was the strength
permeability ofof
a
the magnetic field, 𝜎 was the impressed mechanical stress, 𝜇
vacuum, µr was the relative magnetic permeability of the material, ∆µσ reflected the degradation ofa
was the magnetic permeability of
vacuum,
the 𝜇 was
magnetic the relative
permeability andmagnetic
G was thepermeability of the material,
function describing ∆𝜇 reflected
the influence the degradation
of the mechanical stress
of the
on magnetic permeability
the magnetizability and 𝐺 was
of the material. Other thepapers
functionalsodescribing
discussed the the influence
effects of theof the mechanical
microstructure
stress onby
modified thethemagnetizability
manufacturing process of the on
material. Other properties
the magnetic papers also discussed
[79–93]. the effects
Generally, of the
the hysteresis
microstructure
loss decreased and modified
excess by
lossthe manufacturing
increased process on
with increasing thesize
grain magnetic
[81,82]. properties [79–93].
In the future, it is Generally,
important
to correlate the magnetic properties with the microstructure of the material under differentfuture,
the hysteresis loss decreased and excess loss increased with increasing grain size [81,82]. In the loads,
it is grain
e.g., important to correlate
size, grain the magnetic
orientation properties
and magnetic domain.with the microstructure
Besides, in-situ observationof the ofmaterial under
the dynamic
different loads,
magnetic domain e.g., grain
under thesize, grainconditions
loading orientationwill andprovide
magnetic domain.
a better Besides, in-situ
understanding of theobservation
magnetic
of the dynamic magnetic domain under the loading
properties degradation induced by the manufacturing process [94–100]. conditions will provide a better understanding
of the magnetic properties degradation induced by the manufacturing process [94–100].
Materials 2020, 13, 4583 12 of 21
Figure 13. (a) Measurement principle for the load-related magnetic property; (b) measured hysteresis
Figure 13. (a) Measurement principle for the load-related magnetic property; (b) measured hysteresis
curves at different tensile stresses at 50 Hz for M400-50A [78]. In the experimental system, the force was
curves at different tensile stresses at 50 Hz for M400-50A [78]. In the experimental system, the force
loaded onto the specimens via the clamping jaws, where one side was fixed, and the other side was
was loaded onto the specimens via the clamping jaws, where one side was fixed, and the other side
moveable and controlled by the pressure cylinder. The stress and magnetic flux were applied collinearly.
was moveable and controlled by the pressure cylinder. The stress and magnetic flux were applied
9. Comparison
collinearly. between Current Fusion Welding Methods
Compared to mechanical interlock and glue join, fusion welding is the most reliable method to join
9. Comparison between Current Fusion Welding Methods
the electrical steel laminations for the high-performance motor application. Towards finding the best
Compared
welding solution,tovarious
mechanical interlock
researchers haveand glue join,
compared thefusion
currentwelding is the most
fusion welding reliable
methods method to
[42,51,54,55].
join the electrical steel laminations for the high-performance motor application.
Zhang et al. [51] compared the microstructure, mechanical performance, residual stress and magnetic Towards finding the
best welding
properties of thesolution,
electricalvarious researchers
steel laminations have by
welded compared
laser and the
TIG,current
as shown fusion welding
in Figure methods
14. Because of
[42,51,54,55]. Zhang et al. [51] compared the microstructure, mechanical performance,
the larger heat input, the geometry size of the weld bead in TIG welding was larger than that in laser residual stress
and magnetic
welding, whichproperties
led to higher of the electrical
tensile steel laminations
shear strength. The eddywelded
current by
losslaser and TIG, as
in TIG-welded shown in
laminations
Figure
was 14. Because
larger than thatofinthe larger heat laminations
laser-welded input, the geometry
because size oflarger
of the the weld bead in area
connection TIG welding
betweenwas the
larger than that in laser welding, which led to higher tensile shear strength. The
laminations. Besides, the magnitude of the residual stress in TIG-welded laminations was also larger eddy current loss in
TIG-welded
than laminations was
that in laser-welded larger than
laminations, whichthatled
in to
laser-welded laminations
severe degradation because
of the of the
hysteresis larger
property.
connection area between the laminations. Besides, the magnitude of the residual
To sum up, the heat input of laser was much more concentrated and controllable than that of TIG, stress in TIG-welded
laminations
and was be
laser should also larger heat
a better thansource
that infor
laser-welded
high qualitylaminations,
welding of thewhich led to steel
electrical severe degradation
laminations.
of the hysteresis property. To sum up, the heat input of laser was much more concentrated and
controllable than that of TIG, and laser should be a better heat source for high quality welding of the
electrical steel laminations.
Materials 2020, 13, 4583 13 of 21
Figure Comparison between

Figure 14. Comparison betweenTIG TIGwelding
welding and and laser
laser welding:
welding: (a) Maximum
(a) Maximum shearshear strength;
strength; (b)
(b) eddy
eddy current
current distribution;
distribution; (c) residual
(c) residual stress stress distribution;
distribution; (d) hysteresis
(d) hysteresis curve. curve. The larger
The larger heatin
heat input input
TIG
in TIG welding
welding leads toleads to a cross
a larger largersection
cross section in the welded
in the welded laminations,
laminations, whichwhich then to
then leads leads to larger
larger shear
shear strength
strength and current.
and eddy eddy current. The magnitude
The magnitude of theof the residual
residual stressstress
in TIGinwelding
TIG welding
in thein the far
zone zone far
away
away from
from the the seam
weld weld isseam
largeris than
largerthat
thanin that
laserinwelding,
laser welding,
and theand the hysteresis
hysteresis property property in TIG
in TIG welded
sample has
welded more
sample hassevere
moredegradation than thatthan
severe degradation in laser-welded sample [51].
that in laser-welded sample [51].
Leuning et
Leuning et al.
al. [42]
[42] developed
developed aa novel
novel welding
welding strategy
strategy for
for electrical
electrical steel
steel laminations
laminations using
using the
the
statistical distribution of single laser welding spots alongside common linear welding
statistical distribution of single laser welding spots alongside common linear welding lines across the lines across the
entire height
entire height of
of the
the laminations,
laminations, rather
rather than
than the
the commonly
commonly usedused welding
welding techniques
techniques of of perpendicular
perpendicular
lines that connect the whole laminations. The authors compared the
lines that connect the whole laminations. The authors compared the novel welding strategy novel welding strategy
withwith
the
the conventional
conventional ones,ones, as shown
as shown in Figure
in Figure 15.15.
TheThe experimental
experimental resultsshowed
results showedthat thatring
ringcores
cores with
with
perpendicular welding
perpendicular weldinglines hadhad
lines a lower loss and
a lower better
loss andmagnetization than both regarded
better magnetization than bothmodifications
regarded
with distributed welding spots at low frequencies, which was due to the
modifications with distributed welding spots at low frequencies, which was due to the mechanicalmechanical residual stress
state of the
residual ring
stress cores
state of induced
the ring by theinduced
cores thermal by impact of welding.
the thermal impact Additionally,
of welding. the volume of the
Additionally, the
affected of
volume microstructure was smaller for was
the affected microstructure the welding
smaller forlines.
theAt increasing
welding frequencies,
lines. the eddy
At increasing current
frequencies,
component
the became
eddy current dominant became
component and the dominant
relative lossandincrease became
the relative distinctly
loss increasesmaller
became fordistinctly
the spot
welded samples.
smaller for the spotThewelded
researchsamples.
result proved that the result
The research presented
provednovel welding
that strategy was
the presented novel promising,
welding
especially as an approach for the high frequency applications.
strategy was promising, especially as an approach for the high frequency applications.
Materials 2020, 13,
Materials 2020, 13, 4583
x FOR PEER REVIEW 14 of
16 of 21
23
Figure 15. Comparison between line-welded laminations and spot-welded laminations: (a) Ring core 1,
Figure 15. Comparison between line-welded laminations and spot-welded laminations: (a) Ring core
two linear welding lines; (b) ring core 2, four linear welding lines; (c) ring core 3, spirally oriented
1, two linear welding lines; (b) ring core 2, four linear welding lines; (c) ring core 3, spirally oriented
welding spots; (d) ring core 4, statistical distribution of welding spots; (e) cross section of the line weld;
welding spots; (d) ring core 4, statistical distribution of welding spots; (e) cross section of the line
(f) cross section of the spot weld; (g) magnetic loss at 50 Hz and 1000 Hz and magnetic induction
weld; (f) cross section of the spot weld; (g) magnetic loss at 50 Hz and 1000 Hz and magnetic induction
strength of 1.0 T for different cores. Magnetization curves of Ring cores 1–4 at different frequencies:
strength of 1.0 T for different cores. Magnetization curves of Ring cores 1–4 at different frequencies:
(h) 50 Hz; (i) 1000 Hz [42]. The inner diameter of the Ring laminations was 48 mm and the outer
(h) 50 Hz; (i) 1000 Hz [42]. The inner diameter of the Ring laminations was 48 mm and the outer
diameter was 60 mm. As shown in (h,i), the magnetic polarization at a specific magnetic field strength
diameter was 60 mm. As shown in (h,i), the magnetic polarization at a specific magnetic field strength
follows the descending order of Ringcore 1, Ringcore 2, Ringcore 3 and Ringcore 4.
follows the descending order of Ringcore 1, Ringcore 2, Ringcore 3 and Ringcore 4.
Vegelj et al. [55] developed and presented an experimental system for a new technique of adaptive
Vegelj et al. [55] developed and presented an experimental system for a new technique of
and pulsed laser welding of electrical steel laminations, as shown in Figure 16. The system was
adaptive and pulsed laser welding of electrical steel laminations, as shown in Figure 16. The system
based on on-line monitoring of the gap positions between the electrical laminations and thus enabled
was based on on-line monitoring of the gap positions between the electrical laminations and thus
the precision welding at the interface of the electrical steel laminations. The experimental results
enabled the precision welding at the interface of the electrical steel laminations. The experimental
showed that the developed pulsed spot welds produced lower specific power losses and increased the
results showed that the developed pulsed spot welds produced lower specific power losses and
relative permeability of the samples in comparison with the conventional continuous laser welding
increased the relative permeability of the samples in comparison with the conventional continuous
that was widely used in industrial production. This method brought advantages to the production
laser welding that was widely used in industrial production. This method brought advantages to the
as well as to the final product and had great potential to be implemented in industry, though much
production as well as to the final product and had great potential to be implemented in industry,
work should be done for optimization. Ziegler et al. [101] concluded that quality control was also
though much work should be done for optimization. Ziegler et al. [101] concluded that quality control
important for improving the welding quality, where process monitoring could be integrated into the
was also important for improving the welding quality, where process monitoring could be integrated
welding system to control the quality and to optimize the parameters accordingly. The optical, spectral,
into the welding system to control the quality and to optimize the parameters accordingly. The optical,
thermal and acoustic sensors, which were increasingly being used separately or in combination,
spectral, thermal and acoustic sensors, which were increasingly being used separately or in
were particularly suitable for this purpose. For the evaluation of the measurement data, the intelligent
combination, were particularly suitable for this purpose. For the evaluation of the measurement data,
approaches, e.g., machine learning, promised great potential. For the large-scale application of these
the intelligent approaches, e.g., machine learning, promised great potential. For the large-scale
novel welding technologies, it is important to have a comprehensive investigation about the welding
application of these novel welding technologies, it is important to have a comprehensive
quality, microstructure, mechanical properties and magnetic properties. Besides, the cost of both the
investigation about the welding quality, microstructure, mechanical properties and magnetic
welding system and welding each stator should also be considered, together with the robustness of the
properties. Besides, the cost of both the welding system and welding each stator should also be
welding process and the life of the welding system.
considered, together with the robustness of the welding process and the life of the welding system.
Materials 2020, 13, 4583 15 of 21
Figure 16.
Figure Comparison between
16. Comparison between line-welded
line-welded laminations
laminations andand adaptive
adaptive pulsed-laser
pulsed-laser spotspot welded
welded
laminations: (a) Classic continuous welding; (b) adaptive continuous welding; (c)
laminations: (a) Classic continuous welding; (b) adaptive continuous welding; (c) classic pulsed classic pulsed
welding; (d)
welding; (d)adaptive
adaptivepulsed
pulsed welding.
welding. A typical
A typical weldweld on laminations
on laminations produced
produced by: (e)pulsed-
by: (e) classic classic
welding method; (f) adaptive pulsed-laser welding method. (g) the specific power losses (PS) and(PS)
pulsed-welding method; (f) adaptive pulsed-laser welding method. (g) the specific power losses (h)
andrelative
the (h) the relative permeability
permeability (µr) as (µr) as a function
a function of the of the total-pulse
total-pulse energy
energy for a for
realastack
real stack
weldedwelded
withwith
the
the classic,
classic, continuous-welding
continuous-welding technique
technique (triangles)
(triangles) andand adaptive
adaptive pulsed
pulsed method
method (squares)
(squares) [55].[55].
10. Summary and Future Development
10. Summary and Future Development
A comprehensive investigation about the effects of the joining process on the performance of the
A comprehensive investigation about the effects of the joining process on the performance of the
stator is required. The mechanical strength, fatigue life, and magnetic properties of the joined electrical
stator is required. The mechanical strength, fatigue life, and magnetic properties of the joined
steels are the indicators for the performance evaluation, especially the values of these indicators at an
electrical steels are the indicators for the performance evaluation, especially the values of these
elevated temperature. Besides, the cost of each joining method also should be identified.
indicators at an elevated temperature. Besides, the cost of each joining method also should be
Much more work should be conducted to reveal the mechanism for magnetic properties
identified.
degradation. The in-situ experiment may be a useful method to measure the magnetic properties of
Much more work should be conducted to reveal the mechanism for magnetic properties
the joined electrical steels. For example, the temperature distribution in the joined electrical steels
degradation. The in-situ experiment may be a useful method to measure the magnetic properties of
may be in-situ measured by the thermal imager [102], which could be used to validate the energy loss
the joined electrical steels. For example, the temperature distribution in the joined electrical steels
distribution in the electrical steels calculated by the thermal finite element model. The variation of the
may be in-situ measured by the thermal imager [102], which could be used to validate the energy loss
magnetic domain in the electrical steel at the external load condition under the alternating magnetic
distribution in the electrical steels calculated by the thermal finite element model. The variation of
field environment may be in-situ measured by the neutron grating interferometry [103], magnetic force
the magnetic domain in the electrical steel at the external load condition under the alternating
microscopy [104], magneto-optical indicator film [105], which could help understand the stress induced
magnetic field environment may be in-situ measured by the neutron grating interferometry [103],
magnetic properties degradation.
magnetic force microscopy [104], magneto-optical indicator film [105], which could help understand
Besides, there is still a huge space to optimize the process of joining the laminated electrical steels.
the stress induced magnetic properties degradation.
More experiments could be conducted to build the relationship map between the process parameters
Besides, there is still a huge space to optimize the process of joining the laminated electrical steels.
and performance of the joined laminations, and the simulation model could help to understand the
More experiments could be conducted to build the relationship map between the process parameters
mechanism underlying the experimental phenomena.
and performance of the joined laminations, and the simulation model could help to understand the
In the current simulation model for welding of the laminated electrical steels, the birth and death
mechanism underlying the experimental phenomena.
element technique was adopted to describe the rapid increase of the thermal contact conductance when
In the current simulation model for welding of the laminated electrical steels, the birth and death
the interfaces between the laminations were melted due to laser irradiation. Though this method could
element technique was adopted to describe the rapid increase of the thermal contact conductance
characterize the effects of interfaces on the heat transfer during the welding process, the gap filling
when the interfaces between the laminations were melted due to laser irradiation. Though this
and residual stress evolution process still could not be analyzed. Finally, the thermal-mechanical-fluid
method could characterize the effects of interfaces on the heat transfer during the welding process,
coupled model will be developed to have an in-depth understanding of this welding process.
the gap filling and residual stress evolution process still could not be analyzed. Finally, the thermal-
Most of the current research focused on evaluating the performance of the welded laminations,
mechanical-fluid coupled model will be developed to have an in-depth understanding of this
while did not reach the performance of the actual motor. The effects of the welding process on the
welding process.
performance of the motor investigated by both experiment and simulation are the future trend [38],
Most of the current research focused on evaluating the performance of the welded laminations,
which could build a direct relationship between the welding process and the final performance of
while did not reach the performance of the actual motor. The effects of the welding process on the
the motor.
performance of the motor investigated by both experiment and simulation are the future trend [38],
which could build a direct relationship between the welding process and the final performance of the
motor.
Materials 2020, 13, 4583 16 of 21
Author Contributions: Conceptualization, H.W. (Hongze Wang); resources, H.W. (Hongze Wang), Y.W. and
H.W. (Haowei Wang); data curation, C.X.; writing—original draft preparation, C.X. and H.W. (Hongze Wang);
writing—review and editing, C.X., H.W. (Hongze Wang), Y.W. and H.W. (Haowei Wang); visualization, C.X.;
supervision, H.W. (Hongze Wang); funding acquisition, H.W. (Hongze Wang), Y.W. and H.W. (Haowei Wang).
All authors have read and agreed to the published version of the manuscript.
Funding: This work is financially supported by National Natural Science Foundation of China (52004160 and
52075327), the National Key Research and Development Program of China (2016YFB1100103), Science and
Technology Commission of Shanghai Municipality (“Sailing Program”, 20YF1419200), Natural Science Foundation
of Shanghai (20ZR1427500) and SJTU Global Strategic Partnership Fund (2020 SJTU-KTH).
Conflicts of Interest: The authors declare that they have no known competing financial interests or personal
relationships that could have appeared to influence the work reported in this paper.
Data Availability Statement: The present manuscript is a review paper and does not contain original data.
All data presented in the paper have been referenced appropriately.
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Joining of the Laminated Electrical Steels in Motor Manufacturing: A Review

Article in Materials · October 2020

Cunjuan Xia Hongze Wang

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Phase transformation in thermal processing of material View project

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Keywords: electrical steel; joining and welding; microstructure; magnetic property;

Materials 2020, 13, 4583; doi:10.3390/ma13204583 www.mdpi.com/journal/materials

Figure 3. Schematic of the fusion welding process [40].

Joining Method Research Content Year Reference

3. Characteristics of the Joined Zone

7. Eddy Current Loss Increase Induced by the Joining Process

7. Eddy Current Loss Increase Induced by the Joining Process

Figure Comparison between

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