Vehicle Systems Powered by Sintered Components
Engineered sintered components lend themselves well to numerous EV components, including:
All EV powertrains, including fully-electric vehicles and hybrid vehicles, require strong, efficient, compact, and lightweight by-wire application solutions. This makes them prime candidates for sintered components. While steer-by-wire applications were once primarily reserved for vehicles in the luxury class, it has now spread to all classes of vehicles. Powdered metal components are already in-use for many shift-by-wire, brake-by-wire, and steer-by-wire applications.
Electrified Gears and Gear Boxes
A planetary gearbox, which is made up of toothed carriers and high-strength gears, plays a key role in the EV’s mechanical actuator. Powdered metal components help convert the vehicle’s electric signal into the actual force required to clamp down and brake. Because of the enhanced magnetic performance of powdered metal components, they are far more advantageous compared to traditional steels.
Sensors and Cameras
Sensors and cameras aren’t just for autonomous driving. They also help to process important data required for most EVs to change gears, brake, etc. Because powdered metal components are lightweight and durable, they’re ideal for sensor fixtures on the body and chassis of EVs.
Electric pumps and other electromagnetic applications have specific magnetic material requirements. Soft magnetic sintered components provide cost-effective solutions. The magnetic capabilities of powdered metal components also boost pump efficiency.
EVs use either transverse flux or axial flux e-motors. These e-motors require 3D-magnetic flux and therefore need very EV-specific stator designs. Sintered stators are especially useful in this application because the pure iron material used to manufacture these components helps to reduce eddy current losses in the e-motors.
Sintering has numerous applications for EV batteries. For instance, anodes for the vehicles’ lithium-ion can be created from sintering silicon nanopowder. Sintering glass-ceramic powder is also often used as an ion-conducting electrolyte in batteries.
Linear actuators, like other electromagnetic applications in EVs, require precise magnetic material characteristics. Sintered soft magnetic materials, such as iron, meet these specifications.
Cooling and Thermal Systems
Powdered metals support all thermal management systems. This is due to improved thermal behavior from using just one unique material, versus the varied materials or layers in more traditional thermal management systems.
E-Drive Traction Motors
E-drive traction motors have specific requirements for magnetic material characteristics, making powdered metal the ideal solution.
Engineered Sintered Components from Allied Sinterings
At Allied Sinterings, we’ve been a globally recognized leader in powdered and sintered metal manufacturing for decades. Our powder metallurgy manufacturing provides precision engineering, high-quality controls, and cost savings for all EV applications and motion control solutions. Our facility has the resources and experience to meet the rapidly growing demand for sintered components fueled by the growth of the EV industry. Contact us today to learn more.