Abstract: A busbar for high conductivity distribution of electrical power within a power module of an electric vehicle (EV). The busbar may include a plurality of multilayer composites having copper-graphene laminations. One or more of the multilayer composite may include a first copper-graphene lamination having a plurality of graphene layers disposed between a plurality of copper layers, a second copper-graphene lamination having a plurality of graphene layers disposed between a plurality of copper layers, and a carrier substrate disposed relative to the first and second copper-graphene laminations.

Abstract: A computer-implemented method, when executed on data processing hardware, causes the data processing hardware to perform operations. The operations include i) via application of a machine learning algorithm to a micrograph representative of a metallic material, detecting clusters of dendrite arms in the metallic material and generating an image frame based on the micrograph and representative of the clusters of dendrite arms, ii) detecting, via application of a watershed algorithm to the image frame, individual dendrite arms within the clusters of dendrite arms, iii) applying at least one filter to the image frame, iv) identifying at least one cluster of dendrite arms in the image frame that satisfies the at least one filter, and v) generating, for the at least one cluster of dendrite arms, a cluster profile including at least an average dendrite arm spacing (DAS) value for the at least one cluster of dendrite arms.

Abstract: An induction rotor assembly is provided. The induction rotor assembly includes a laminated stack, a plurality of foils, a plurality of conductor bars, a first end ring, and a second end ring. The laminated stack includes a body with an outer circumferential surface with a plurality of grooves extending from the first end to the second end. Each one of the plurality of foils is disposed within one of the grooves. Each of the foils is disposed between each of the conductor bars and each of the grooves. Each of the plurality of conductor bars includes a first conductor end and a second conductor end. The first end ring mates with a surface of each first conductor end. The second end ring mates with a surface of each second conductor end, and the plurality of conductor bars extends between the first end ring and the second end ring.

Abstract: Provided is a kit for rapid detection of avian leukosis virus subgroup J (ALV-J) based on a CRISPR/Cas13a system. The method is based on the combination of the CRISPR/Cas13a system and recombinase aided amplification (RAA) for ALV-J detection. An oligonucleotide probe is designed as a substrate for CRISPR/Cas13a trans-cleavage and produces a detectable signal. The method can substantially improve detection sensitivity by amplifying a detection signal twice by RAA and T7 transcription. The detection method further exhibits excellent specificity, allowing for clear differentiate from other avian viruses. It does not require expensive experimental equipment and special laboratory environment, and it is rapid and efficient. The method is of great significance for biological research and on-site detection of ALV-J.

Abstract: A composite wire bundle for a stator winding, a stator including a composite wire bundle, and a method of forming a composite wire bundle. The composite wire bundle includes a plurality of copper wires, wherein each of the plurality of copper wires include a first surface. The composite wire bundle also includes a copper-graphene multilayer composite applied to the first surface of each of the plurality of copper wires, wherein the copper-graphene multilayer composite includes a second surface. Further, the composite wire bundle includes a fluoropolymer matrix formed around the second surfaces and a jacket encapsulating the fluoropolymer matrix.

Abstract: A brake rotor includes a body, at least one thermal barrier, and a substrate. The body includes at least one braking surface and a plurality of venting channels. The at least one thermal barrier is disposed on the at least one braking surface. The at least one thermal barrier includes a first ceramic layer having a first density and a first porosity, and a second ceramic layer having a second density and a second porosity. The second density is less than the first density, and the second porosity is greater than the first porosity. The second ceramic layer is selectively engaged with the at least one braking surface of the body. The substrate is selectively coupled to first ceramic layer of the at least one thermal barrier in a first state of the body. The brake rotor is free of the substrate in a second state of the body.

Abstract: An electric machine including a stator and a rotor. The rotor is configured to rotate within the stator and includes: a core; a first end ring at a first end of the core and a second end ring at a second end of the core; conductors extending across the core that electrically connect the first end ring and the second end ring; and a first reinforcing ring that is cast within the first end ring and a second reinforcing ring that is cast within the second end ring.

Abstract: A method for controlling a pump motor associated with a component molding system includes applying a selected activation energy to the pump motor, driving, with the pump motor, a casting medium from a source to a mold through a casting medium delivery system, delivering the casting medium into a mold cavity, detecting one or more casting medium delivery parameters in the casting medium delivery system, detecting one or more casting medium mold parameters in the mold cavity, sending a first plurality of signals representing the casting medium delivery parameters to a controller, sending a second plurality of signals representing the casting medium mold parameters to the controller, processing the first plurality of signals and the second plurality of signals to determine pump motor control parameters, and adjusting the selected activation energy to the pump motor based on the pump motor control parameters.

Abstract: An electronics module housing is provided. The electronics module housing includes a high-pressure die cast integrated power electronics (IPE) housing component having at least one coating-free mating surface. The integrated power electronics housing component is formed from an aluminum alloy including silicon between 6.5 wt. % and 7.5 wt. %, copper between 0.05 wt. % and 0.30 wt. %, magnesium between 0.1 wt. % and 0.6 wt. %, iron between 0.20 wt. % and 1.50 wt. %, chromium more than 0 wt. % and less than 0.30 wt. %, and manganese more than 0 wt. % and than 0.15 wt. %.

Abstract: A spreader configured to be implemented in a die of a die casting system is disclosed. The spreader includes: a substrate; a hardening layer and an oxide layer. The hardening layer includes: a nitride and carbide layer disposed on the substrate and increasing hardness; and a white layer disposed on the nitride and carbide layer. The oxide layer includes: an inner transition layer disposed on the white layer and increasing resistance to oxidation; and an outer iron oxide layer disposed on the inner transition layer and increasing resistance to soldering during die casting of a part in the die casting system.

Abstract: A conductive composite stator unit for an electric motor of a vehicle is provided. The stator unit comprises a stator core comprising a body having a first core end and an opposing second core end. The stator unit further comprises a plurality of conductive bars extending from the first core end to the second core end. Each conductive bar comprises a straight portion disposed in one of the slots such that the respective conductive bar is in contact with the stator core. Each conductive bar comprising a central portion and an outer layer disposed thereabout for electrical current to flow therethrough relative to the longitudinal axis, the outer layer comprises at least two copper-graphene (Cu-Gr) layers. Each Cu-Gr layer comprises a copper layer and a graphene layer. The stator unit further comprises an insulator layer disposed about each of the plurality of conductive bars.

Abstract: A conductive cable for a battery electric vehicle is provided. The conductive cable comprises a plurality of first members in alignment to define a longitudinal axis of the conductive cable. Each first member comprises a first conductive wire about which a first outer layer is disposed for electric current to flow therethrough relative to the longitudinal axis. The first outer layer comprises a first metal substrate having a first side and an opposite second side. The first outer layer comprises a first copper-graphene (Cu-Gr) multilayer composite disposed on the first side and a second Cu-Gr multilayer composite disposed on the second side of the first metal substrate. Each first conductive wire comprises a first metallic material. The plurality of first members is disposed together along the longitudinal axis to define a cable bundle. The conductive cable further comprises a non-conductive layer disposed about the cable bundle.

Abstract: A method of making a rotor assembly includes positioning a thin-film composite with a transfer member into engagement with a slot surface of a corresponding slot of a multitude of slots. The slots are formed around a perimeter of a laminated steel stack with each of the slots in the laminated steel stack being defined by a slot surface. The method also includes placing the laminated steel stack in a casting mold, having cavities for defining a pair of end rings on opposite ends of the laminated steel stack that are in fluid communication with the slots.

Abstract: Aspects of the disclosure include a tempo-spatial manipulation of ultrasonics (TSMU) for solid-state battery manufacturing and solid-state batteries manufactured using the same. An exemplary vehicle includes an electric motor and a battery pack electrically coupled to the electric motor. The battery pack includes a solid-state battery cell that includes an anode having a major surface, a solid electrolyte in direct contact with the anode, and an interface between the anode and the solid electrolyte. The interface is subjected to TSMU including a first ultrasonics phase at an emission angle parallel to the major surface of the anode, a second ultrasonics phase at an emission angle orthogonal to the major surface of the anode, and a third ultrasonics phase at an emission angle parallel to the major surface of the anode, thereby reducing an air gap between the anode and the solid electrolyte at the interface.

Abstract: A prototype sand-casting system for producing a sand cast prototype that duplicates material properties of a high pressure die casting part is provided. The prototype sand-casting system includes a sand-casting mold, a plurality of ingates in fluid connection with the mold cavity, a runner system, a first furnace, and a second furnace. The plurality of ingates are configured to direct multiple concurrent casting alloys including a first molten metal alloy and a second molten metal alloy into the mold cavity to form the casting. The runner system is fluidly coupled to the plurality of ingates. The first furnace and the second furnace is fluidly coupled to the runner system. The first molten metal alloy and the second molten metal alloy are concurrent casting alloys.

Abstract: An induction rotor assembly is provided. The induction rotor assembly includes a laminated stack, a plurality of foils, a plurality of conductor bars, a first end ring, and a second end ring. The laminated stack includes a body with an outer circumferential surface with a plurality of grooves extending from the first end to the second end. Each one of the plurality of foils is disposed within one of the grooves. Each of the foils is disposed between each of the conductor bars and each of the grooves. Each of the plurality of conductor bars includes a first conductor end and a second conductor end. The first end ring mates with a surface of each first conductor end. The second end ring mates with a surface of each second conductor end, and the plurality of conductor bars extends between the first end ring and the second end ring.

Abstract: An electrical connection for a vehicle and methods of forming an electrical connection for a vehicle. The electrical connection includes a first electrical component including a first joining area. The electrical connection also includes a conductor including a second joining area. The conductor is joined at the second joining area to the first joining area of the first electrical component. In addition, the electrical connection includes a fusion zone formed in the first electrical component in the first joining area. The conductor includes a copper-graphene multilayer composite formed on the surface of the conductor, the composite including at least one of the following composite structures: a) alternating layers of graphene and copper deposited on the substrate, b) graphene particles dispersed in a copper matrix, and c) alternating layers of graphene and copper deposited on a copper foil, wherein the copper foil is wrapped around the substrate.

Abstract: A magnesium (Mg) alloy housing for a drive unit of an electric vehicle (EV) having a drive shaft connected to an electric motor is provided. The Mg alloy housing comprises a body comprising Mg alloy. The body is arranged to house the drive unit of the EV. The housing further comprises a cylindrical hub disposed on the body. The hub has a bore formed therethrough and arranged to couple the drive shaft of the electric motor to the drive unit. The hub comprises a Mg portion having an inner surface. The hub further comprises an aluminum (Al) insert having an outerface. The Al insert is arranged to be disposed on the Mg portion such that the inner surface is aligned with the outerface defining a weld interface. The Al insert comprises iron (Fe) and Manganese (Mn) and having a Fe/Mn weight ratio of between 1:20 and 1:30.

Abstract: Aspects of the disclosure include copper-graphene (Cu-Gr) multilayer composite (CGMC) current collectors and methods of manufacturing the same. An exemplary vehicle includes an electric motor and a battery pack electrically coupled to the electric motor. The battery pack includes a battery cell with a cell pouch having therein a plurality of stacked anode current collectors alternating with a plurality of stacked cathode current collectors, and an active material dispersed within the cell pouch to cover the current collectors. Each of the anode current collectors is a CGMC current collector including a copper foil substrate having a top surface and a bottom surface. The copper foil substrate is pure copper. A graphene layer is directly on at least one of the top surface and the bottom surface of the copper foil substrate and a plated copper layer is directly on the graphene layer.

Abstract: A method for mass-producing graphene composite vehicle components is provided. The method includes injecting a first flux into molten metal contained in a furnace using a first flux injection system and injecting a graphene flux into the molten metal using a second flux injection system. The method includes agitating and homogenizing the molten metal and the graphene flux within the furnace using an agitator. The method includes transferring the molten metal into a mold having an electromagnetic stirring system and then stirring the molten metal with the electromagnetic stirring system until the molten metal solidifies. The electromagnetic stirring system maintains homogenization of the molten metal and the graphene flux.