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.

See our SMC solutions

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.

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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:

  1. Less complexity and assembly
  2. Better thermal behavior made from one unique material
  3. 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.

Accelerating automotive electrification

Electrified gearboxes face higher requirements for torque and rotation speeds. An RPM of 14,000 to 16,000 will be normal and will result in high-frequency noise without any ‘masking’ sounds from the engine.

Surface-densified PM gears provide significant benefits in performance and NVH, which is a crucial aspect in the development of modular drivetrain platforms for hybrid and electrical vehicles. We have demonstrated that densified PM gears perform equal to steel gears for durability, transitory torque and torsion fatigue while offering lower noise levels.

NVH improved eDrive gears

Pumps are needed for cooling and actuation purposes in automotive engines and transmissions. 

The GKN DPM approach decreases the number of components using an integrated system with new motor technology. Above the optimized thermal behavior, the improved efficiency allows a customer to build smaller sized electric pumps.

Thermal behaviour improved pumps

The use of Soft Magnetic Composites (SMC) powder allows the development of compact eMotor stators with new 3D geometries.

These functionality-improved SMC stators enable compact Axial Flux machines (AFM) that offer a significant downsizing potential against conventional eMotor pump systems.

Reduce size and weight of fully integrated E-pumps

Get in touch

Jürgen Neumair
Jürgen Neumair
Your sales contact for e-motors
Get in touch with Jürgen