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Engineers’ Hub for Electric Motor Efficiency

 

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.

 

 

trends in manufacturing auto parts

Electric Motor Efficiency Through Materials & Processes

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:

  • E-bikes
  • E-scooters
  • E-motorcycles

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.

Resource: 3 Trends in Manufacturing Auto Parts: Does Powder Metal Have a Place?

electric motor efficiency - soft magnetic composite 1

Design Flexibility

A powder metal part is born when premixed iron alloy is pressed into a desired shape to produce 3D structures. Because it’s a material-efficient, net-shape process, it’s dramatically easier and more efficient to design with powder metal vs. machining or another subtractive process.

Think about how engineers place electric car motors on the front or rear axle -- space is at a premium. Today it’s possible to redesign the motor with powdered metal components to use space more efficiently. You can use the extra space to include other components or just make the entire product smaller and lighter!

Advanced powder metallurgy manufacturers are here to help e-motor designers meet the increasing demand for smaller electric and hybrid motors.

Resource: Electric Motor Efficiency & 4 Other Uses for Soft Magnetic Composite

electric motor efficiency - feather

Lighter Weight

Manufacturers are committing to further optimizing electric drive components to reduce weight in e-vehicles.

A smaller motor is naturally lighter. Using fewer and smaller components is where powder metal shines. 

Resource: A Groundbreaking Rotor Material

electric motor efficiency soft magnetic composite - compass

Rapid-Response Applications

Developments in ultra-high-temperature sintering coupled with advanced materials can create solenoids and relays used in actuators that need more rapid response times.

Additionally, rotors used in brushless DC motors can achieve high magnetic performance when you use sintered soft magnetic powders.

Resource: What Is Sintered Soft Magnetic Material?

induction vs permanent magnet motor efficiency-1

Magnetic Performance

Soft magnetic materials are the perfect match for motors and stators. They possess competitive magnetic properties, but with higher electrical resistivity.

Use one of the many unique grades of soft magnetic composite as your new electric motor material to attain the highest frequencies possible.

Resource: Beginner’s Guide to Soft Magnetic Composites

electric motor efficiency - car

Cost Reduction

Cutting costs for a growing variety of pressed and sintered motor components remains the heart of powder metallurgy.

If your current design is cumbersome and producing excessive scrap, consider a redesign with powder metal. PM produces a more compact design with virtually no leftover material -- scrap waste rarely exceeds 3%.

Sometimes powder metallurgy can even reduce the number of parts needed in an assembly traditionally made with electrical lamination steel.

Resource: Soft Magnetic Composites: A Visual Crash Course on Improving Motor Efficiency

What’s Your Motor Design Challenge?

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.

MEET YOUR CONSULTANTS

fran hanejko electric motor efficiency

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. 

tom freemer - electric motor efficiency

Tom Freemer, our Director of Technology & Business Development, has worked as a design and material development expert for a world-leading raw material supplier. Today, Tom collaborates with design engineers across several industries to create innovative PM solutions, whether it’s through an advanced manufacturing technique or a unique material alloy. He graduated from Penn State University in 2000 with a degree in materials engineering.

If you have questions relating to the PM manufacturing process, fill out the form and get in touch with Tom.

 

Applications for DC & AC Motor Stators

Modern powder metal (PM) components first appeared in self-lubricating bearings and Lionel Train wheels. But the powder metallurgy process has evolved, just as DC and AC motor stators have evolved. 

Motor Weight Reduction Via Powder Metallurgy Materials

Weight is a concern in just about every metal-based product today. Notably, cars have been on a strict diet for years now, and powder metallurgy materials have had an important role to play in it.

The Advantages of Sintering With a S.M.A.R.T. Furnace

Famous automakers around the world rely on the sintering process in powder metallurgy to improve their components’ performance and economic efficiency. New advances in sintering can lead to even higher overall performance for those automakers -- as well as other industries.

5 Things to Tell Your Powder Metallurgy Supplier About Your Design NOW

Powder metallurgy (PM) is increasing in popularity for both magnetic and structural  applications. But no matter how many design proposals come across the desk of a PM manufacturer, there’s always a unique challenge.

8 Common Secondary Operations in Powder Metallurgy

Making components through powder metallurgy is an exercise in trimming the fat. Its ability to create a net shape part means you can skip some -- or all -- secondary operations, including machining.

Sizing in Powder Metallurgy: Ensure a Net Shape Part

Sintering is a wonderful way to improve part properties via powder metallurgy (PM). But like any other manufacturing process, it’s not perfect. A component that goes through a sintering furnace will change size or otherwise become distorted. 

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