Proterial, FEV Validate Amorphous Alloy Traction Motor

Proterial and FEV Validate New xEV Motor Concept

On October 5, Proterial and FEV announced the joint validation of a design concept for an electrified vehicle (xEV) traction motor using an amorphous alloy and high-performance heavy rare earth-free neodymium sintered magnets. Simulations indicated that the concept could improve motor efficiency, raise maximum output to 300 kW, and reduce motor weight by approximately 27% compared with a reference motor rated at around 230 kW. The development combines advanced magnetic materials and a higher-speed motor architecture to target greater output while reducing the mass of the traction system.

Amorphous Alloy Enables Higher-Speed Motor Design

The reference motor uses silicon steel laminations for its core and represents a typical power range for commercially available battery electric vehicles (BEVs). In the evaluated concept, the silicon steel core is replaced with an amorphous alloy characterized by low iron losses. The change also enables the motor's maximum rotational speed to increase from 14,900 rpm to 20,000 rpm. According to the simulation results, this combination of reduced core losses and higher rotational speed contributes to the concept's potential efficiency and output improvements while supporting a substantially lighter motor design compared with the reference model.

Heavy Rare Earth-Free Magnets Address Resource Risks

The motor concept also incorporates Proterial's heavy rare earth-free neodymium sintered magnets, which are designed to combine high remanence with high coercivity. Removing heavy rare earth elements from the magnet formulation can reduce exposure to associated resource and procurement risks while maintaining the magnetic characteristics required for traction motor applications. The magnet technology therefore forms an important part of the overall material strategy alongside the amorphous alloy motor core. Together, these technologies are being evaluated as a route toward higher-performance electric motors with lower mass and reduced dependence on heavy rare earth materials.

Joint Development Continues in Germany

Proterial and FEV will continue jointly investigating the use of advanced materials in motors and complete drive systems. The companies are presenting their findings at the Aachen Automotive Colloquium in Germany, held in Aachen from October 5 to 7. A model of the evaluated motor structure is also being displayed at FEV's booth during the event. The continued collaboration is intended to extend the evaluation beyond the demonstrated motor concept and explore how advanced materials can be applied across broader electric drive-system architectures.

Industry Impact & Outlook

The development highlights how advanced magnetic materials can support higher-output and lighter electric traction motors while addressing material-sourcing considerations. For automakers and motor developers, the combination of an amorphous alloy core, higher rotational speed, and heavy rare earth-free magnets could provide another pathway for improving power density and efficiency in xEV drive systems. The next phase of the collaboration will focus on continued application studies involving motors and complete drive systems, making further validation important for determining how effectively the concept can transition from simulation and demonstration toward practical vehicle applications.

Frequently Asked Questions

What did Proterial and FEV validate for xEV applications?
The companies validated a design concept for an xEV traction motor using an amorphous alloy core and heavy rare earth-free neodymium sintered magnets. Simulations indicated potential efficiency improvements, a maximum output of 300 kW, and approximately 27% lower weight than a reference motor rated at around 230 kW. The concept also increases maximum rotational speed from 14,900 rpm to 20,000 rpm. Proterial and FEV plan to continue evaluating advanced materials for motors and complete drive systems, with their findings presented at the Aachen Automotive Colloquium in Germany.