Electrical machine with improved loss characteristics and method of making same

Abstract

An electrical machine includes a stator and a rotor. The stator has a central opening that is configured to receive the rotor. The rotor includes a generally cylindrical first section comprising a first material mounted on an axially extending shaft within the central opening. The rotor further includes a second section having a second material of a predetermined thickness that is plated integrally over at least a portion of the first section. The second material has a higher electrical conductivity relative to the first material. In certain embodiments, the electrical machine may include a stator support structure having a clamping member comprising a first material and configured to rigidly position the stator around the rotor. The stator support structure further includes an electrically conductive layer comprising a second material plated integrally over the clamping structure, wherein the second material has a higher electrical conductivity relative to the first material.