The thesis addresses the development of a TIG welding process for hairpin copper conductors of electric motor stators intended for small-series production. The aim of the research was to establish a technological solution for producing high-quality and repeatable welded joints and to determine suitable welding process parameters while considering the quality requirements of the welded joints. Within the scope of the research, a prototype tool for positioning the conductors was developed and experimental welding of test specimens was carried out using different combinations of welding parameters, where welding current and welding time were considered as the main parameters. The quality of the welded joints was evaluated by analysing porosity and weld cross-sections using computed tomography (CT), electrical resistance measurements, and tensile testing. Metallographic specimens were also prepared, and metallographic analysis of the welded joints was performed together with hardness measurements. Based on the obtained results, the optimal combination of welding parameters ensuring adequate weld quality was determined. Welding of an electric motor stator was also carried out, followed by process optimisation and analysis of the time efficiency of the operations. The results showed that the developed TIG welding process enables the production of high-quality welded joints and represents a suitable technological solution for welding electric motor stators in small-series production.
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