Key Takeaways
- Aperam introduces a new “slinky” production method for creating iron-cobalt (FeCo) alloy components for electric motors.
- This innovative technique significantly reduces material waste, cutting scrap to 10–30% compared to up to 70% using traditional methods.
- The slinky process enhances power density and torque for electric vehicles and eVTOL aircraft, while reducing motor size, supporting sustainable transportation goals.
New Production Method for Electric Motors
Aperam has unveiled an innovative “slinky” production method aimed at manufacturing iron-cobalt (FeCo) alloy stators and rotors specifically for high-performance electric motors. This new approach leverages an in-plane helical winding process previously utilized for electrical steel, adapting it to work with FeCo alloys known for their challenging forming properties yet exceptional magnetic performance.
The “slinky” method distinguishes itself by utilizing continuous strips to form motor components, as opposed to traditional stamping from sheet metal. By employing a combination of linear stamping and in-plane helical bending techniques, Aperam is able to produce slinky stators and rotors while significantly minimizing metal waste. The production process dramatically cuts material scrap to a range of 10–30%, a stark contrast to conventional methods, which can result in wastage of up to 70% of these high-cost materials.
According to Aperam, integrating the slinky production technique with FeCo alloys yields considerable benefits, including a power density increase of +35% for electric Vertical Take-Off and Landing (eVTOL) aircraft, a torque boost of +25% for hypercars, and a reduction in motor size by -15%. These enhancements are particularly vital for aviation applications, where weight constraints are paramount.
The innovative approach is based on Aperam’s AFK family of FeCo alloys, which includes variants such as IMPHY AFK1, AFK18, and AFK502R. Frederic Mattei, CEO of Alloys and Specialties as well as Chief Innovation Officer at Aperam, emphasizes the unique advantages of FeCo alloys despite their high costs. “FeCo alloys offer unparalleled magnetic performance, but their cost has historically limited their efficient use,” he stated. The introduction of the “slinky” method not only reduces waste considerably but also facilitates the design of more efficient electric motors. This, in turn, aids customers in addressing the increasing demands for sustainable transportation solutions.
Through this innovative production method, Aperam aims to revolutionize the electric motor manufacturing landscape by providing more efficient and environmentally friendly options that align with the growing emphasis on sustainability in the transportation sector.
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