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

    High induction, high permeability, and low loss soft magnetic alloys and stacks for improved motor, powertrain, and system-level performance


    Tailor the benefits of your motor with high-performance materials

    Our soft magnetic alloys allow designers to optimize torque and power density with high efficiency for improved system-level performance. As a drop-in solution, our Hiperco® alloys and stator and rotors stacks can increase torque up to 25% without altering motor design. These alloys provide 25% higher induction, better permeability, and 30% lower losses than conventional electrical steel. Due to their high power density, designers utilize our soft magnetics to decrease the motor size up to 30%, without sacrificing torque.

    Our engineering team partners with designers to ensure the maximum benefits of high-performance soft magnetic alloys are realized. Our materials help improve motor efficiency by up to 3% and power density by 30%. They also allow motors to run 10-20°C cooler during operation, offering better thermal management options that improve motor life. Our stack processing techniques, including lamination, heat treatment, bonding, and assembly techniques, have been optimized for quality and process yields for scale-up. We implement the best production method for your product given the unique performance requirements, design maturity, and volume demands based upon our expansive process datasets and experience.

    Optimal Power Density Across Various Motor Drive Frequencies

    Up to 400Hz

    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.

    Optimal Power Density Across Various Motor Drive Frequencies

    400Hz to 1200Hz

    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.

    Optimal Power Density Across Various Motor Drive Frequencies

    Above 1200Hz

    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.

    Optimal Power Density Across Various Motor Drive Frequencies

    Ultra-High-Speed Motors

    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.

    electric rotors and stators

    Stator and Rotor Stacks from Prototype to Production

    Carpenter Technology’s decades-long expertise in specialized materials and stack processing offers unique high-performance stack solutions for our customers. Our engineers have a deep understanding of the structure-property relationships along with knowledge in various processing technologies. Lack of expert knowledge of iron-cobalt stack processing can result in rotors and stators that perform only marginally better than standard electrical steel. Our alloys and stack manufacturing methods for dimensional control, high-strength, and tailored magnetic properties support the most demanding motor design requirements and production tolerances, providing you with the stack responses you need.


    Related Resources

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