Best-in-Class Materials for High-Efficiency, Power-Dense Motors

Traditional aerospace electrical systems operate at 400Hz. This standard enabled sufficient power density with size and weight reduction given overall power requirements. The first generation of electric vehicles feature electric drive frequencies between 60 and 400Hz.

Laminations 0.15mm and thicker are typically used in this frequency range. Stator and rotor stacks produced from these laminations have low losses at these frequencies, providing sufficient performance and optimal value.

More-electric aircraft, hybrid aircraft, and similar applications with high power usage requirements use higher frequency architectures. Future generations of electric vehicles are expected to move to this category. Higher frequency systems increase overall power density so motor size and weight can be minimized for higher power outputs.

Thinner laminations are required to mitigate the higher losses in soft magnetic materials at these frequencies. Motor designers typically opt for stacks with either 0.15mm or 0.10mm laminations, depending upon motor design and stator and rotor stack magnetic performance. Our stack processing technologies have been engineered for optimal performance of stators and rotors produced from thin laminations.

These higher frequencies are common for motors that must deliver high torque and power output in an extremely compact and lightweight format. They are commonly used in racing for turbochargers, energy recovery devices, and electric traction motors. Hybrid and fully electric propulsion aircraft designs are exploring these higher frequencies.

Very thin layers of soft magnetic material are needed to manage the escalating losses as frequencies increase. For applications above 1200Hz designers use 0.10mm or thinner laminations for stator stacks. Carpenter Electrification has engineered our material and stack processing technologies for optimal performance of stators and rotors produced from thin laminations.

Certain motor designs operate with lower torque and realize high power density from their high operating speeds. This is common for medical motors used in surgical drills, bone saws, and other handheld power tools.

These motors typically use alloys such as High Permeability 49 or HyMu 80 that possess superior permeability and low core loss. Our soft magnetic alloy and motor stack solutions offer excellent sensitivity and responsiveness and enable high motor speeds with low vibration and noise. While creating higher torque and power, our alloys have low core loss for lower heat generation and extended use. Our high-performance materials also enable the design of smaller, lighter-weight compact motors and tools.