Engineers’ Hub for Electric Motor Efficiency

Powder Metallurgy, Then and Now

The Metal Powder Industries Federation recently republished an interesting article about the early history of powder metallurgy (PM) that was originally printed in a 1944 issue of the Saturday Evening Post. It notes that General Motors began making significant quantities of PM parts during WW2 as a way to cost effectively mass produce many small intricate parts that helped in the war effort. These parts were often difficult to cast or machine; thus, PM offered the ability to mass produce these components while meeting all design strength requirements in a cost-effective manner.

Engineers who are tasked with designing and specifying electric motors for new and updated applications are now facing three interdependent challenges: optimizing operating efficiency, simplifying the manufacturing processes to reduce cost, and addressing the emerging concern of recyclability and sustainability.

History of Power Tools

Until after World War II, the US power tool market was largely focused on the industrial metal working and wood working industries. The home and professional markets were largely left unaddressed. It wasn’t until the 1950s that equipment makers realized the potential of the home and professional sectors. Shown below is a photograph of three drill types. The image on the left is a brace and bit. Prior to the early 1950s, this was perhaps the most common drill type used by homeowners. (Yes, it was my dad’s and yes it still works!) On the right is a ¼-inch corded electric drill, typically used by homeowners around the 1950s, and in the center is a late 90s cordless electric drill. The technology only continues to progress!

The move to electric mobility is well past passenger cars.

In 2012, the total energy consumption of the United States was estimated to be 96 quadrillion BTUs (96 x 10^15). Figure 1 illustrates how this usage breaks down by sector. At the time of this study, energy consumed by the transportation sector was almost entirely from gasoline or diesel fuels. In the remaining residential, commercial and industrial sectors, it is estimated that approximately 35% of the energy is consumed by electric motor systems.

In the intricate array of modern manufacturing, the Powder Metallurgy (PM) industry stands as a dynamic force, continually shaping the future as a sustainable metal forming technology. As we navigate through the current landscape of PM, it becomes evident that innovation is not merely a choice but a necessity.