The Innovate UK's Makeit Lighter with Less competition found that engineers seeking to significantly improve motor efficiency and performance could benefit from aluminum matrix composites (AMC).

According to foreign media reports, Innovate UK's "Makeit Lighter with Less" research and development competition found that engineers seeking to significantly improve motor efficiency and performance could benefit from aluminum matrix composites (AMC).

Metal matrix composites are metal materials reinforced by high performance auxiliary materials. Generally speaking, auxiliary materials are in the form of long fibers, short fibers or granules.

The project is carried out by Alvant, a British expert in aluminum matrix composites, together with GEAviation, YASA Motors and the National Composite Center. The weight loss of the rotor of the axial flux motor is 40% and the power inertia ratio of the rotor is improved. In addition, the number of assembly lines is also reduced, thus shortening the assembly time.

With the development of electrification, automobile manufacturers are demanding ways to optimize motor efficiency. For example, by improving the efficiency of the 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 total costs.

Alvant's proprietary aluminium matrix composites allow components to be precisely optimized for strength-to-weight ratios and firmness-to-weight ratios when needed. Alvant's proprietary Advanced Hydraulic Forming (ALPF) method can selectively enhance part of the assembly using one of the performance materials to approach the net shape of the manufacturing method. Alternatively, Alvant materials can be used as discrete inserts in components to achieve cost savings.

By using aluminium matrix composites in the rotor, the weight of Alvant is reduced in the application of axial flux motor. Reducing the weight of this part means that it can be streamlined. Engineers can reduce the number of fixed bolts needed and reduce the material usage and assembly time.

Although the Innovation UK/YASA project focuses on motor rotors for passenger cars, Alvant's own research projects have demonstrated the potential of using aluminium matrix composites in high-stress or high-temperature applications such as aerospace, automotive, national defense, consumer goods and sports equipment.