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Stator Insulation Testing for Appliance Motors with Aluminum Windings: Applying Solutions to Root Causes of Failure

A number of appliance manufacturers have recently removed their copper (Cu) motor stator winding material and replaced them with aluminum (Al) to reduce product costs in the competitive global appliance market. Although a reduction in the motor cost can be achieved, it is accompanied by a noticeable increase in the failure rate due to stator insulation breakdown.