Abstract: A process and a system for welding rotor coils are presented. A plurality of rotor coils are arranged on a table of a machine. A welding tool welds the rotor coils on one end using a Friction Stir Welding process. Transition pieces are each arranged between the rotor coils to create a continuous welding path. A run-off tab is placed at an end of the welding path. The welding tool is changed to a milling tool after completion of the welding. The milling tool traces back along the welding path to separate the rotor coils. The milling tool may be changed to the welding tool to repeat the process for another end of the rotor coils. The process is completely automatic and controlled by a control unit.

Abstract: A process and a system for welding rotor coils are presented. A plurality of rotor coils are arranged on a table of a machine. A welding tool welds the rotor coils on one end using a Friction Stir Welding process. Transition pieces are each arranged between the rotor coils to create a continuous welding path. A run-off tab is placed at an end of the welding path. The welding tool is changed to a milling tool after completion of the welding. The milling tool traces back along the welding path to separate the rotor coils. The milling tool may be changed to the welding tool to repeat the process for another end of the rotor coils. The process is completely automatic and controlled by a control unit.

Abstract: A method is provided for applying a layer (12) of electrical insulation material to a surface (14) of a conductor (16). One embodiment of the method involves preparing the surface (14) of the conductor (16), followed by cold spraying a plurality of mica particles (28) onto the surface (14) of the conductor (16). Another embodiment of the method involves preparing the surface (14) of the conductor (16), followed by cold spraying a plurality of boron nitride (BN) particles onto the surface (14) of the conductor (16).

Abstract: A method is provided for applying a layer (112) of material to a surface of a non-metallic substrate (116) to enhance a performance characteristic. The method includes applying glass backing (114) to the non-metallic substrate (116) and cold spraying mica or boron nitride (BN) particles (128) onto a surface of the glass backing (114). A conductive tape is also provided, which is formed with the method. The conductive tape includes a first layer of an insulation material (114?), where the first layer is formed from a backing including a fiber-based or polymer backing with resilient and flexible properties for storage in a rolled form and a layer of mica particles or boron nitride particles. The conductive tape further includes a second layer (142?) positioned over the layer of particles, and formed from an electrical conductor material.