Abstract

The thin sheets of CRNO electrical steel are widely used in motors of electric vehicles (EV) and several domestic appliances. The thin sheets of thickness 0.5 mm are stacked and welded across the edges to form the stator core for use in the electric motors. The present work aims to study the distortion variations observed on the CRNO thin sheets under different range of welding current (30–110 A). The stacks comprising of thin sheets of CRNO with total thickness of 50 mm (100 sheets × 0.5 mm) post-welding are observed for evaluating the distortion on the surface of stacks. The measurement of surface distortion is done using a surface profilometer for observing the variation on the surface of stacks. The maximum and minimum surface distortion in the range 0.66 to −0.27 mm and 0.17 to −0.08 mm, respectively, is observed for weld samples at different welding current. The distortion of thin CRNO sheets results in deterioration of material properties affecting the performance of electrical systems. The present study aims to establish a relation between the surface distortions at different locations across the weld zone with varying input welding current.

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