Quality Assurance Testing for Screening Defective Aluminum Die-cast Rotors of Squirrel Cage Induction Machines

The recent trend in squirrel cage induction motor manufacturing is to replace fabricated copper rotors with aluminum die-cast rotors to reduce manufacturing cost to stay competitive in the global market. Porosity in aluminum die-cast squirrel cage rotors is inevitably introduced during the die cast process. Porosity can cause degradation in motor performance and can lead to a forced outage causing irreversible damage in extreme cases. Many off-line and on-line quality assurance test methods have been developed and applied for assessment of rotor quality. However, years of experience with the existing test methods revealed that they are not suitable for quality testing or capable of providing a quantitative assessment of rotor porosity with sufficient sensitivity. In this paper, a new off-line test method capable of providing sensitive assessment of rotor porosity is proposed. It is shown that rotors with minor and distributed porosity that are difficult to detect with other tests can be screened out during manufacturing. The proposed method is verified through a 3 dimensional finite element analysis and experimental testing on closed and semi-open slot aluminum die cast rotors of 5.5 kW induction motors with porosity.