How to Do Motor Stator Welding?

The stator core is an important component of the motor. Its quality and welding process has an important impact on the performance and life of the entire motor. Correct stator core welding methods can improve the efficiency and reliability of the motor and extend the service life of the motor.

What Is Electric Motor Stator Welding?

The welding of the motor stator lamination core refers to arranging the core laminations according to certain rules and fusing and connecting them through heating and pressure. The principle is to melt the iron chips to produce slight extrusion deformation on the surface layer, so that force is generated between the chips, thereby achieving the purpose of solidification.

laser welding

Types of Motor welding

Our automatic stamping machine punching motor stator and rotor lamination stacks. Once the motor stator and rotor lamination stamping finish, we use riveting, cleating, gluing, self-bonding, and welding to stack our laminations. We commonly use welding including:

Laser Welding

We provide a high-precision laser welding technique that utilizes a focused laser beam to melt and join the edges of the stator laminations. This method offers high-quality control, making it ideal for intricate stator designs and thin laminations.

In industries with high production volumes, laser welding is one of the most frequently used technologies for hairclip welding of thick wires.

TIG (Tungsten Inert Gas) and MIG (Metal Inert Gas) Welding

TIG +MIG welding compared with laser welding, is an arc welding process that uses an electric arc to generate the heat necessary for welding. These methods are versatile and widely used in stator welding for various motor sizes and materials.

TIG Welding: TIG welding involves using a non-consumable tungsten electrode to create an arc. It offers precise control over the welding process and is suitable for thin laminations.

MIG Welding: MIG welding employs a consumable wire electrode that feeds continuously. It’s known for its speed and is commonly suitable for thicker laminations. MIG welding provides excellent weld penetration and is suitable for larger motor components.

TIG welding motor stator

Resistance Welding

Resistance welding is another widely used method in motor stator production. It involves passing an electrical current through the stator laminations, causing them to heat and fuse together.

For high-volume production, techniques like resistance welding or projection welding may be more efficient than manual welding techniques.

Spot Welding

Spot welding is a variation of resistance welding, where small, localized welds (spots) are made at specific points on the stator laminations. It’s suitable for smaller motors or when a limited number of welds are required.

Process of stator stacks with laser welding

Surface Treatment

Before welding the stator core, the surface of the core needs to be cleaned to remove oil and impurities on the surface to ensure that the welding surface is clean and smooth.

Alignment and Fixturing

Arrange and assemble the core laminations to ensure that the contact area between the lamination is sufficient. When arranging and assembling, you also need to pay attention to the direction and position of the motor laminations.

Fixturing is essential to hold the laminations securely in place during the welding process, preventing misalignment or movement.

Laser Setup

Set up the laser welding machine according to the specific parameters required for the stator stack welding. This includes adjusting laser power, pulse duration, and beam focus.

Laser welding machines may also include vision systems to precisely position the laser beam relative to the laminations.

Laser Welding

Activate the laser and direct the focused laser beam onto the edges of the welding laminations.

As the laser beam makes contact, it rapidly heats the edges of the laminations, causing them to melt and fuse together.

The welding process typically involves moving the laser beam along the edges of the laminations to create a continuous weld. The speed and movement need to be controlled to ensure consistent and defect-free welds.

Quality Control and Inspection

Immediately after welding, conduct a visual inspection to identify any weld defects, such as incomplete fusion or cracks.

Non-destructive testing methods, like ultrasonic testing or dye penetrant testing, may also ensure the quality of the welds.

automatic laser welding machine

Post-Welding Treatment

Depending on the application and material, post-welding treatments such as stress relieving or annealing may be required to relieve residual stresses and improve the overall properties of the weld.

Looking for Reliable Motor Laminations and Expert Welding Services?

Motorneo offers precision solutions for laser welding motor cores. We have a state-of-the-art automatic welding workshop and deliver superior-quality motor stator and rotor lamination stacks. Whether you need DC motors, high voltage motors, switched reluctance motors, servo motors, linear motors, or any other motors, our custom-designed laminations and precision welding services are engineered to meet the highest standards.

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The welding of the motor stator core plays a very important role in the performance and stability of the motor. Its welding quality directly affects the working effect and life of the motor. Therefore, the welding of the motor stator lamination stacks must be performed by professionals to ensure welding quality and reliable technology.


What are the primary materials for motor stator construction?

Electrical steel, often called silicon steel, is the most commonly used material for motor stator cores. It is favored for its excellent magnetic properties, which are crucial in efficiently conducting and maintaining the magnetic flux produced by the motor.

Copper is widely used for the winding coils within the stator. Its excellent electrical conductivity makes it ideal for creating magnetic fields when electric current passes through it.

Insulation materials such as varnish, polyester, polyimide, and epoxy are used to coat the stator’s copper windings. These materials prevent electrical shorts between the winding turns and other metal parts of the stator.

How does welding affect the performance of a motor stator?

Improper welding can lead to defects such as porosity, cracks, and incomplete fusion, which can weaken the stator structurally and electrically, leading to reduced efficiency, increased heat generation, and potential motor failure.

Can motor stator welding be automated?

Yes, motor stator welding can be automated, especially in high-volume production settings. Automated welding helps achieve consistent quality, reduce labor costs, and increase production efficiency.

what is the motor Hairpin welding process?

Motor hairpin welding is a specialized welding process used in the manufacturing of electric motors, particularly for the assembly of the motor’s stator. This process is named after the hairpin-like shape of the copper or aluminum wires used in the stator winding.

Try to contact us for high-quality motor cores in China.