The die-cast copper motor rotor – a new copper market opportunity
Induction motor manufacturers have long known that substitution of copper for diecast aluminum in the rotor squirrel cage would significantly reduce motor losses and improve the electrical energy efficiency. Aluminum is readily die-cast to produce the complex squirrel cage within and around the iron laminations of the rotor. Copper is much more difficult to die-cast due to its high melting temperature which leads to premature die failure. The work reported here addresses the die life problem in die casting electrical grade copper. A number of candidate high temperature die materials were surveyed. Computer simulation of the cyclic thermal and stress gradients in dies provided insight into the “heat checking” failure mechanism and how it could be minimized or avoided. A nickel-base alloy die system preheated to and operated at ~625°C has been developed and shown to greatly extend die life compared to die steels operated conventionally. A die insert heating and insulation system was developed to make extended runs possible. Copper motor rotors were die cast over a range of machine operating parameters in joint effort with several motor manufacturers. Motor test results showing the predicted 15 to 20% reduction in motor losses and reduced motor operating temperatures are presented.
Some economical comparisons between aluminium and copper squirrel cages
Serious thought is being given to the use of die cast copper cages; this is why the cost of copper for cage manufacture might become reasonable, even for small motors. Eight optimum designs are presented; two different powers, two different objective functions (initial price or total price including the price of future losses), and two cage materials (copper and aluminium) have been considered. Various components of prices are compared. >
Pyrite multiple-sulfur isotope evidence for rapid expansion and contraction of the early Paleoproterozoic seawater sulfate reservoir
Abstract Earthʼs oxygenation is often described in terms of two unidirectional steps at the beginning and end of the Proterozoic Eon, separated by a long-lived intermediate redox state. Recent work defines a more complicated path to oxygenation, exemplified by an apparent drop in oxidation state following the early Paleoproterozoic Lomagundi carbon isotope excursion. The timing of this proposed drop in oxidation state is not well constrained, and it is not clear how it relates to redox conditions during the remainder of the Proterozoic. Here we present a study of pyrite multiple-sulfur isotopes, supported by Fe speciation and organic carbon isotopes, from early Paleoproterozoic black shales. We find evidence for the rapid expansion of the seawater sulfate reservoir during the Great Oxidation Event at ca. 2.3 Ga followed by a subsequent contraction in the size of the seawater sulfate reservoir at ca. 2.05 Ga. This scenario is consistent with the emerging view of a rise and fall in surface oxidation state during the early Paleoproterozoic. Comparison of our new data to other records of the seawater sulfate reservoir suggests that the elevated sulfate concentrations that characterize the early Paleoproterozoic did not return until the late Neoproterozoic.