Electric motor design is about more than just reducing cost -- it’s about the chance to get innovative and exceed performance expectations.
If you’re already experimenting with new electric motor solutions that are a little "different,” consider incorporating powder metallurgy (PM) into your plan. Whether you’re looking for electric motor efficiency or cost reduction, chances are a PM solution exists.
Use this hub as a resource for understanding the advantages of powder metallurgy for motor applications vs. competing technologies like electrical steel laminations. Below you can learn more about the untapped potential powder metallurgy holds for motor makers -- and how you can use it to push the boundaries of your design.
Using powder metal parts to cut costs is nothing new. Using powder metal components to further the “electrification” of transportation and other electromagnetic applications is the new frontier for driving performance and cost-efficiency to new heights.
In the case of transportation, these opportunities go far beyond the traditional automobile. Powder metallurgy processes and materials are seeing more use in:
Powder metal materials and processes can optimize both AC and DC motors -- everything from axial flux motors to magnetic torque tunnels. Basically, anything that needs to be small and efficient needs to include metal powder parts.
In the race to innovate, electric motor designers no longer need a “good enough” solution, they need a great solution. Powder metallurgy’s benefits go hand in hand with cutting-edge design.
How can Horizon help you brainstorm a solution? Share your design challenges via the form, and an expert engineer will get back to you shortly.
Fran Hanejko is an industry-leading expert who works with Horizon as our Senior Advanced Materials Engineer. Fran has decades of experience in powder metallurgy, including managing customer applications for a world-leading raw material supplier. He graduated from Drexel University in 1974 with a master’s degree in materials engineering.
Contact Fran with your materials questions by filling out the form on this page.
The evolution of powder metal (PM) bearings, and ultimately modern powder metallurgy, dates back to the late 1920s when the Chrysler Corporation needed a higher strength bearing for the clutch of their new inline 6-cylinder engines. During this time, they developed a sintered copper, tin, and graphite bearing with 25% porosity which was then filled with oil via vacuum impregnation. This provided greater load carrying capabilities than existing materials. Chrysler was awarded a patent on the material and processing and the modern PM industry was born.
Sintering is a powder metallurgy processing step with plenty of untapped potential.
We’ve previously discussed how high-temperature sintering can take your DC electromagnetic component’s properties to a level conventional sintering can’t match. Through recent advances in powder metallurgy -- like ultra-high-temperature sintering (UHTS) -- an even greater leap forward is possible:
All manufacturing processes and technologies have their share of pros and cons. Yet, when it comes to powder metallurgy, few processes have changed for the better in a relatively short period of time.
Today, the advantages of powder metallurgy rival many conventional manufacturing technologies -- even machining -- when it comes to the production of high quantities.