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6 Phase Hairpin

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We get a lot of requests asking specifically for a "6 phase hairpin" when they really have no idea why, they have just been told its "Better".
I guess some companies promote them like they are the end-all of alternators. In my opinion, it’s really because they don't have the capacity to design a stator of their own. I think they buy whatever "shelf parts" WAI has or their distributor of choice and "Hairpin" just sounds cool, and it’s got to be better right, ....
Is a hairpin a better design than a loop wound stator”? 
Yes, absolutely. It is a better design. But...

They are too small to be a better overall design compared to a properly designed large case GM stator. IF they were the size of an AD244 then yes, they would be a "Better" alternator
Some cars just don’t have a housing option for a large case GM, and some don’t have a housing option for a hairpin.   4.2 Trailblazer is one.  There is no such housing for a 4.2L in a hairpin style. On cars that have both options, I ALWAYS do a Large Case GM style (Suburban for example)

Hairpins do NOT have more output at idle.  That is probably the biggest myth of all about them.  The ONLY hairpin that has more output at low rpm is a large case 270 Amp. They are just too small to do 320+ amps AND do good at a low rpm idle (Cars that idle at 900+ rpm are outliers, and any alt will idle good on them)
Look how much LESS copper there is in a hairpin (See pic of the leads side by side)  

They have 6 leads of a single conductor.  Our large case GM has 3 leads of 8 wires each. 6 wires VS 24 wires in our Large Case GM, the cross-sectional area of wire is not even close. 
Any stator out there that has 8 leads per phase is an Iraggi Alternator design that I came up with back in the late 1990's.  It’s called a "Dual POW wind"  (Dual Progressive Offset Wind.) It’s actually "Quad Wound" but the machine winds 2 coils at once, It maximizes slot fill and cross sectional area of wire per phase
A hairpin stator  is literally a single piece of wire cut thousands of times and welded back together on the bottom side of the stator 
There is only 1 attribute that a hairpin stator has over a loop wound stator, and that’s the space between slots.  The hairpin has approximately .050 of space between slots and the slot wound has approximately .120 of space. 
The hairpin gap can be much smaller because the wire is not passed through the gap during assembly, it passed through from the top of the lamination. The wire on a loop wound must fit through the gap to go into the slot.  The hairpin is a much better use of space. It all comes down to the cross-sectional area of the stator I.D.  (Look at the inside of the two stators to see the difference)
I’ll be more than happy to clarify ANY info you guys have questions about. I just want you all to have what’s best for your system
These are my opinions, so don’t slam me for posting this as a fact 🙂




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