Innovate UK ’s “Make it Lighter with Less” project research and development competition found that engineers seeking to significantly improve the efficiency and performance of motors can benefit from aluminum-based composites (AMC).
Metal matrix composites are metal materials reinforced with high-performance auxiliary materials. Generally, the form of the auxiliary material is long fiber, short fiber or granular.
This project was jointly carried out by Alvant, a British aluminum-based composites expert, with GE Aviation, YASA Motors, and the National Composites Center, and achieved 40% on the rotors of axial flux motors. Weight reduction while increasing the power to inertia ratio of the rotor. In addition, the number of assembly lines has been reduced, thereby reducing assembly time.
As electrification trends continue, automakers are demanding ways to optimize motor efficiency. For example, by increasing the efficiency of torque and speed, the energy consumption of the vehicle is finally determined. The industry faces the challenge of identifying ways to improve efficiency and performance while simplifying manufacturing and reducing overall costs.
Alvant's proprietary aluminum-based composites allow components to be precisely optimized for strength-to-weight and stiffness-to-weight ratios when needed. Alvant's proprietary Advanced Hydroforming (ALPF) method can use one of the performance materials to approach a net shape manufacturing method to selectively enhance a portion of a component. Alternatively, Alvant materials can be used as discrete inserts in components to achieve cost savings.
By using aluminum-based composite materials in the rotor, Alvant has reduced weight in axial flux motor applications. The reduced weight of the part means that it can be streamlined, and engineers can reduce the number of fixing bolts required and reduce material use and assembly time.
Although the innovative UK / YASA project focuses on passenger car motor rotors, Alvant's own research projects demonstrate the use of aluminum-based composites in a number of high-stress or high-temperature applications such as aerospace, automotive, defense, consumer products, and sports equipment Deliverables.