Comprehensive benchmarking of laser welding technologies including novel beam shapes and wavelengths for e-drive copper hairpins

Laser welding is the industrially accepted method for the joining of Cu hairpin windings in the production of electric drives. High brilliance laser beams are scanned over the bare ends of the Cu wires producing a rapid connection through deep penetration remote welding. Despite being an accepted manufacturing method, laser welding of Cu hairpins still requires detailed studies concerning manufacturing productivity and quality. As the availability of novel laser sources with higher power levels, new wavelengths, and beam shaping capabilities increase, the need for benchmarking studies emerges. In this work, six different laser welding systems were compared in terms of process productivity and quality during the welding of Cu hairpins used for automotive traction. The different solutions presented power levels from 3 to 6 kW, with wavelengths from near infrared (NIR) to visible, including in source dynamic beam shaping. The weld bead formation was observed through high-speed imaging. The welds were analyzed in terms of their geometry, internal defects, and most relevantly for their mechanical strength. The results showed advantages of each of the employed system while the laser systems providing the highest irradiance profile produced the fastest weld with more elevated mechanical strength independently from the wavelength

Methodological comparison of laser stripping solutions with contemporary pulsed lasers for e-drive copper hairpins

The electric drives used in traction applications employ conventionally pure Cu bars bent to the required form, inserted in the stator and welded by a laser at the extremities. These extremities, which are referred to as Cu hairpins, should be stripped off from the electrically isolating polymeric enamel. Laser stripping is industrially used to remove the enamel from the Cu surface. Pulsed wave lasers are employed for the purpose with a large variety of solutions industrially available to the end users. The peculiar process may give way to material removal by surface heating for instance using infrared radiation (IR) or ultraviolet (UV) lasers or an indirect material expulsion via near-infrared (NIR) sources. Accordingly all major laser sources, namely CO2, active fiber, active disk, and Nd:YAG at different wavelengths, may be used for the purpose. Such laser sources possess very different characteristics regarding the pulse durations, power levels, and beam diameters. As newer laser system solutions are made available, the need for methods and experimental procedures to compare the process performance also increases. This work compares 7 different hairpin stripping solutions based on contemporary pulsed laser sources along with a detailed comparative analysis method. Initially, the 7 laser sources are used for hairpin stripping. The process quality is analyzed through surface morphology, chemistry, and the mechanical strength upon laser welding. Productivity and efficiency indicators are collected. Using the collected data, the work proposes system configurations for three different scenarios prioritizing quality, productivity, and cost

Assessing the Efficiency of Molecular Markers for the Species Identification of Gregarines Isolated from the Mealworm and Super Worm Midgut

Protozoa, of the taxon Gregarinasina, are a heterogeneous group of Apicomplexa that includes ~1600 species. They are parasites of a large variety of both marine and terrestrial invertebrates, mainly annelids, arthropods and mollusks. Unlike coccidians and heamosporidians, gregarines have not proven to have a negative effect on human welfare; thus, they have been poorly investigated. This study focuses on the molecular identification and phylogeny of the gregarine species found in the midgut of two insect species that are considered as an alternative source of animal proteins for the human diet: the mealworm Tenebriomolitor, and the super-worm Zophobasatratus (Coleoptera: Tenebrionidae). Gregarine specimens were isolated from the gut of both larval and adult stages of T.molitor specimens, as well as from Z.atratus larvae. The morphological analyses were restricted to the identification of the different parasite morpho-types, likely corresponding either to different life-cycle stages or to alternative gregarine species. The samples were also used for the DNA extraction necessary for their genetic characterization. Finally, the efficiency of different molecular markers (i.e., 18S rDNA gene alone or combined with the Internal Transcribed Spacer 1) was assessed when applied either to gregarine species identification and to phylogenetic inference