The growing trend toward automotive electrification drives a long agenda of changes and challenges for both internal combustion engine vehicles (ICE) and the diverse range of full or partially electrified vehicles (full EV and Hybrid EV). Innovative, cost effective solutions are used to address these challenges, and our Powder Metallurgy (PM) technology can make this trend unstoppable.
PM expertise drives automotive electrification
Electric vehicles (EVs) and hybrid electrical vehicles (HEVs) are more than a trend and will further accelerate over the coming years. Automotive electrification drives a long agenda of changes and challenges for both internal combustion engine vehicles (ICE) and the diverse range of full or partially electrified vehicles (EV and Hybrid EV).
Some challenges are:
- Weight reduction
- Thermal management for all electrified components and systems
- A strong demand for compact, on-demand actuated auxiliary systems
- New requirements for Noise Vibration Harshness (NVH) improvements
Innovative, cost effective solutions are needed to address these challenges, and our Powder Metallurgy (PM) technology offers new and better opportunities.
Soft magnetic composites for electric motors
Demand is soaring for engineers to design e-drive and mobility applications that deliver high power and torque density and efficiency while creating savings in weight and size.
Soft magnetic composite (SMC) materials offer a new solution in powder metallurgy to produce superior performance in transverse flux motor and axial flux motor designs.
New opportunities for integrated designs
Without electrification, it will not be possible to achieve the global regulation targets for CO₂ reduction.
Even for traditional combustion engines, more electrified on-demand subsystems are used to meet CO₂ requirements. Looking at the EV and HEV sector, emerged drivetrain and chassis architectures set new requirements for size, thermal management, and noise behavior of components.
What looks like a huge number of diverse challenges is actually a great opportunity to rethink and explore the advantages of an old technology in these newly defined applications.
Our advanced PM technology offers smart solutions for several car components. This includes ePumps and eMotors for the growing number of on-demand actuated fly-by-wire systems (also called X-by-wire). Other applications are NVH-optimized gears for eDrive transmissions and other lightweight solutions through light materials and designs.
Design for PM has some strong answers for electrification
Our advanced Design for PM (DPM) approach offers an opportunity to review the design of complete sub-systems and components that are subject to the new challenges coming with electrification:
- Reduce weight and size
- Improve NVH and thermal behavior
What in the past might have required the assembly of many components made from various materials, today can be achieved with one integrated, PM-optimized design.
PM optimized components can offer three benefits at once:
- Less complexity and assembly
- Better thermal behavior made from one unique material
- A much more compact design
DPM looks at the part's function and achieves product optimization of the overall performance in a collaborative approach with our customers. Our team of experienced engineers is continuously exploring the role that our technology can play in the development of the increasing EV and HEV applications.