Improving Conductivity

While Cu has better thermal conductivity SS is poor. So, .001" Cu cladding won't help much.

The stator core consists of a "stack" of disks. The outer diameter of this core, although ground to achieve required dimension, has a relatively rough surface (peaks and valleys). This surface cannot be polished, as start reaction would cause the stator to rotate, nor could heat sink compound be applied for this reason.

My thinking is the copper cladding would conform to the surface irregularities of the stator core to increase the total area of contact when the housing contracts around the core after installation by heating.

Thermal resistivity between heat generator and coolig medium has following components:

-own resistance of stator

- resistance of interface (what you want to reduce)

- resistance of housing

- convective effect between housing and fluid

You can by wht you suggest only reduce the interface resistance.

The problem is that aluminum has a conductivity in the range of 250 W/mK and SS inthe range of 16.3 (carbon steels are in the range 39...50). Even if you reduce the interface resistance to zero the huge difference between aluminum and stainless steel will not be compensated. You cannot avoid derating!

lynlynch and nick name, thank you for your clarification. I understand now that even if I where to increase the outer surface area of the housing (with fins for example), It would not affect the rate of heat transfer.

Here you are wrong we discussed ONLY hom material changes affect heat transfer and that what you had the inyention to do will have as results.

If you modify the transfer area from housing to fluid you modify an other term of the mentioned so that you can in some respect compensate the conduction improving the convection. But such a modification has to quantified not only estimated. You could also look at the thickness since the thermal resistance is proportional to t/λ, a thinner wall will have a smaller resistance. Stainless steels have higher mechanical limits than aluminum. Making ALL changes yoou may come to a lower derating.