An electrically conductive aluminum diecast alloy and an induction motor rotor made of the diecast aluminum alloy. The aluminum alloy includes commercially pure aluminum and a sufficient weight percent (wt%) of Copper (Cu), Magnesium (Mg), and Silicon (Si) to precipitate a 0.1 wt% to 5.0 wt% of a thermally stable Q-phase precipitate, AlwCuxMgySiz, after age hardening. Wherein w = about 14.3 at% to about 23.82 at% of Al; x = about 5.90 at% to about 9.52 at% of Cu; y = about 35.30 at% to about 42.85 at% of Mg; and z = about 28.57 at% to about 35.30 at% of Si. The induction motor rotor includes an aluminum squirrel cage rotor diecast onto a laminated electrical steel. The aluminum diecast squirrel cage rotor includes about 1.0 wt% of thermally stable Al.sub.5Cu.sub.2Mg.sub.8Si.sub.6 after age hardening.

A rotor of a dynamo-electric rotary machine includes a rotor core arranged concentrically to a rotor axis and including slots filled with electrically conductive material. A front ring is arranged at a front axial end of the slots and includes electrically conductive material, and a rear ring is arranged at a rear axial end of the slots and includes electrically conductive material. A rotor-core-distal surface of the front ring and/or rear ring has a bevel in axial direction from an outer circumference to an inner circumference, with the bevel defined by a bevel angle having a value of 3° to 30°. A support element is at least partially connected to the front and/or rear ring with a positive fit and pressed thereon axially, with the support element being supported on a shaft and having a radial end which terminates at a radial end of the front and/or rear ring.

A method for producing a rotor of an asynchronous machine includes providing a rotor lamination stack having grooves extending parallel to a rotor axis of the rotor, inserting conductor rods into the grooves such that the conductor rods protrude from end faces of the rotor lamination stack, wherein a twisting tool is placed at each of the end faces onto the protruding conductor rods and the twisting tools are twisted relative to each other, where the parallel grooves with the corresponding conductor rods also extend obliquely after the twisting and where the twisting tools are formed such that the protruding conductor rods remain parallel to the rotor axis when an oblique profile of the stack is produced, removing the twisting tools, providing first and second short-circuit washers, and axially pressing the short-circuit washers onto the conductor rods projecting perpendicularly from the end face of the rotor lamination stack.

A number of variations may include at least one mold portion that may define a first cavity, a circular gating system, and at least one sprue. The circular gating system may surround the first cavity and define a continuous in-gate from the circular gating to the first cavity. The at least one sprue and at least one vent may be in fluid communication with the circular gating system and the first cavity.

A rotor of a rotary dynamoelectric machine incudes a magnetically conductive body, having substantially axially running slots distributed around the circumference. A squirrel cage includes electrical conductors which are arranged in the slots. The electrical conductors are electrically contacted at the two end faces of the rotor by short-circuit rings. The magnetically conductive body includes a base body and at least two further additional bodies, which axially adjoin the base body. A first one of the at least two additional bodies directly axially adjoins the end face of the base body, and a second one of the at least two additional bodies and optionally any further additional body axially adjoin the first additional body. The slots have radially exposed slot portions in the axial end regions of the rotor such that the conductors can be moved radially outward.

A squirrel-cage rotor manufacturing method capable of suppressing, at the time of performing die-casting, formation of gaps between closing portions and a rotor core at radially outer parts of rotor slots, or generation of a thermal stress in the rotor core as a result of expansion of the closing portions. The squirrel-cage rotor manufacturing method includes: arranging, through die-casting, conductors into rotor slots that are formed along a radially outer part of a rotor core; and performing the die-casting under a state in which radially outer parts of the rotor slots are closed with closing portions made of the same material as a material of the rotor core.

A rotor assembly is provided in which a solid rotor ring is formed at either end of a stack of laminated discs, the solid rotor rings yielding improved electrical and mechanical characteristics in a low weight assembly. The solid rotor rings are fabricated by brazing slugs between the end portions of the rotor bars, the braze joints contacting a large percentage (at least 90%) of the rotor bar end portions.

A rotor for a reluctance machine and a method of producing a rotor for a reluctance machine is provided. The rotor is formed as a soft magnetic element which is cylindrical in shape. The soft magnetic element has recesses for forming flux barriers, one or more flux barriers being at least partially filled with a filler material, and the filler material of said flux barriers extending up to the rotor periphery and forming part of the rotor periphery.

A rotor fabrication method is provided, along with the resultant rotor assembly. The rotor uses pre-fabricated conductive rotor bars in which the ends have been shaped and sized to fit within corresponding end cap receptacles. After assembly, the structure is compressed, thereby achieving mechanical and electrical coupling between the conductive rotor bars and the end caps. Locking members disposed at either end of the assembly maintain the desired level of axial compressive force on the structure.

A method for producing a rotor for an electric rotating machine includes spraying in a rolling manner a first metallic material and a second metallic material, which is different from the first metallic material, onto at least part of a substantially cylindrical outer surface of a shaft body by a thermal spraying method to form on the shaft body a coating which forms at least part of a squirrel cage.