A Study on the Optimal Powder Metallurgy Process to Obtain Suitable Material Properties of Soft Magnetic Composite Materials for Electric Vehicles

This study systematically investigates the impact of the material properties of soft magnetic composites (SMCs) on the powder metallurgy forming process. It proposes a suitable material selection process for various motor types and shapes and determines the optimal forming conditions for each SMC material. This study employed the Taguchi design method to identify key control factors such as powder type, forming temperature, and forming speed, and analyzed their effects on relative density. Simulation results indicated that AncorLam HR exhibited superior properties compared with AncorLam and Fe-6.5wt.%Si. The optimal conditions determined through signal-to-noise ratio (SNR) calculations were AncorLam HR at 60 °C and five cycles per minute (CPMs). Validation through simulation and SEM analysis confirmed improved density uniformity and reduced defects in products formed under optimal conditions. Final prototype testing demonstrated that the selected conditions achieved the target density with minimal variance, enhancing the mechanical properties and performance of the motors. These results suggest that the appropriate application of SMC materials can significantly enhance motor efficiency and reliability.