Transforming ideas
Clad metal solutions
Our new transforming ideas
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Clad Metal Solutions | Kevin Juergens |
Wickeder Westfalenstahl
Motivation
› EU-Regulation to
increase efficiency of
distribution and power
transformers 548/2014
terminated
› Treating our resources
with care
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Status Quo – Copper and Aluminum
› Currently the coil windings in a transformer
system are wound in Copper or Aluminum
› The choice depends on:
› application
› electrical and mechanical requirements
› and periphery
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Characteristics Aluminum
› Advantages
› Disadvantages
›
›
›
›
› Lower mechanical
strength and electrical
conductivity adverse
copper
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Light weight
High heat capacity
Good workability
Anodisation possibility
Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Characteristics Copper
› Advantages
› Disadvantages
› High electrical and
heat conductivity
› Good workability
› Higher mechanical
properties
› Heavy weight
› Typically covered with
an additional
insulation
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Is it possible to combine the
advantages?
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Clad Metal Solutions | Kevin Juergens |
Wickeder Westfalenstahl
Clad Materials
Clad Materials - Process
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Clad Designs
Overlay
2 … 98%
Inlay /
Edgelay
Corelay
S2S
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Clad Metal Solutions | Kevin Juergens | Wickede Westfalenstahl
Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Clad Materials – Samples
Overlay
Inlay
S2S
Corelay
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Clad – Ideas for transformers
1. Electrical connectors
/ busbars
2. Transformer
Enclosures / housings
3. Transformer
windings
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Clad – Ideas for transformers
1. Electrical connectors
/ busbars
2. Transformer
Enclosures / housings
3. Transformer
windings
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
1. Aluminum-Copper Clad
Al-Cu: Easy to contact – Copper to Copper or
Aluminum to Aluminum
Nearly no contact resistance
Cu-Al-Cu: Up to 60% weight reduction possible:
leightweight and cost-saving alternative to full
Copper
Al-Cu-Al:Copper „plus“ a top layer of Aluminum to
dissipate heat
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Clad – Ideas for transformers
1. Electrical connectors
/ busbars
2. Transformer
Enclosures / housings
3. Transformer
windings
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
2. FERAN
› FERAN (Aluminum-Steel-clad)
› Combination of ferritic and electrical conductive
metals
› Good heat reflection
› High (adjustable) corrosion resistance
› High (adjustable) strength
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
2. CUFER
› CUFER (Copper-Steel-Clad)
› High (adjustable) strength
› combination of ferritic and high electrical
conductive metals
› Less specific weight than pure Copper
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Clad – Ideas for transformers
1. Electrical connectors
/ busbars
2. Transformer
Enclosures / housings
3. Transformer
windings
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
3. Aluminum-Copper Clad
› Cu-Al-Cu
› Up to 60% weight reduction possible:
leightweight and cost-saving alternative to pure
Copper
› Contactable like pure Copper
› Less work hardening
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
3. Aluminum-Copper Clad
› Al-Cu-Al
› Anodisable
› Excellent heat dissipation because of Aluminum
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
3. Aluminum-Copper Clad
› Al-Cu-Corelay
›
›
›
›
›
›
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Anodisable
Less short circuit losses
Specific electrical conductivity adjustable
Selective current (heat) management possible
Selective heat transfer possible
Round and square cores possible
Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Excurse: Anodisation
› Electrolytic Oxidation of Aluminum
› No galvanic layer – transformation of Aluminum
surface (Oxide, Hydroxide)
› Thin insulating layer:
› High corrosion resistance
› High flexibility
› High Temperature resistance
› Self-restoring
› Very good heat transmission coefficient
› High bulk factor > 90%
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Anodising of Aluminum Copper Corelay
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
PK Losses: Influence of Copper Proportion
› Transformer / Choke Characteristics
›
›
›
›
›
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P0 (No-load loss)
PK (Short-circuit loss)
S (P0+PK) = 100 %
P0 ~ 15 %
PK ~ 85 %
Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Short Circuit loss reduction of Aluminum-Copper
Corelay in comparison to pure Aluminum
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Transformer winding example with Corelay
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Transformer winding example with Corelay
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Conclusion / summary
› In combination of Aluminum and Copper, a
higher perfomance is possible
› Different clad designs offer many opportunities
for divers applications
› Aluminum including „Copper core“ is anodizible
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Clad Materials – Open the Door to a New
World of Possibilities
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
What about your idea?
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Clad Metal Solutions | Kevin Juergens | Wickeder Westfalenstahl
Keep on Cladding!
Visit us on Booth 1.1D15
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Clad Metal Solutions | Kevin Juergens |
Wickeder Westfalenstahl