COLUMBUS, Ohio—Worthington Steel subsidiary Tempel Steel has developed a process for bonding electrical steel laminations which, when stacked together, form a motor core. The patent-pending technology is designed to improve performance and manufacturing efficiency in automotive and industrial motor applications, according to a release from Worthington Steel.
The Full Surface Bonding™ (FSB™) process applies a thin adhesive layer to the laminations before stacking, creating a strong bond that is reported to help eliminate gaps and improve motor efficiency. The process, described as more efficient, durable, and cost-effective than traditional motor core stacking methods, is said to represent “an important step forward in motor core design and manufacturing.”
“FSB reflects the kind of innovation that strengthens our leadership in electrical steel lamination and helps customers deliver next-generation motor technologies,” said Geoff Gilmore, president and CEO of Worthington Steel, in the release. “This patent-pending process demonstrates how Worthington Steel and Tempel are creating more value for our customers.”
Full Service Bonding is said to offer several advantages versus traditional bonding technologies. The process increases efficiency by reducing wasted energy inside the motor core (lower core loss). It enables quieter, smoother operation by reducing noise, vibration, and harshness (NVH). It also improves thermal conductivity, which may reduce hot spots and extend motor life. The durability of Full Service Bonding—including resistance to heat, fluids, and high pressure—has been proven in testing, the company said in the release.
Thanks to thinner coatings (as little as 2–4 microns versus 5–14 microns with traditional methods), the process is said to allow more active steel in each motor core, supporting greater efficiency and power. By facilitating simpler, more reliable production, it supports faster stamping speeds, longer die life, and flexible sourcing, the release stated.
“FSB offers an efficient alternative to traditional bonding techniques by improving NVH, reducing core losses, and simplifying the stamping process,” said Cliff Nastas, president of Tempel Steel, in the release. “Early feedback from customers suggests it can deliver meaningful performance gains in electric mobility and other advanced applications, as well as improved supply chain resiliency, scalability, and cost competitiveness.”
The process has been validated in Tempel testing and customer trials, and is approved for production applications at multiple automotive OEMs, according to the release.
Worthington Steel describes itself as “a metals processor that partners with customers to deliver highly technical and customized solutions.” Known for its expertise in carbon flat-roll steel processing, electrical steel laminations, and tailor-welded products, the company offers value-added processing capabilities that include galvanizing, pickling, configured blanking, specialty cold reduction, and lightweighting, as well as electrical lamination.