This paper focused on composite technology to bond materials for rotor cores, which require both good magnetic properties and mechanical properties at once, and analyzed diffusion bonding of sintered material and the bonding area as a factor affecting it. It was determined, as a result, that the strength of the bonding zone depends on the bonding area, and diffusion bonding was an effective technique for bonding together different materials like magnetic material and structural material. This report describes the establishment of a sinter diffusion bonding technique that provides satisfactory bonding strength. This was accomplished by improving the bonding area through application of pressure by press fitting of the inner and outer components, which was accompanied by the difference in thermal expansion of the sintered material. Application of the developed material to rotor cores for use in hybrid cars has made it possible to achieve both functionality and strength, to significantly improve productivity, and to reduce costs by 50%.
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