| Abstract Scope |
EWI has developed a novel sintering method called “Resistance-Based Sintering” (RBS) for powder metal products. With cycle times measured in seconds, RBS is significantly faster than traditional techniques. RBS has been successfully demonstrated with titanium, aluminum, steel, and copper. RBS combines mechanical deformation and self-diffusion to achieve rapid, high-quality consolidation. This effort focuses on applying RBS for iron-based soft magnetic materials used in electric vehicle (EV) motors, where magnetic performance directly impacts efficiency. Iron-phosphorus alloys are especially promising due to phosphorus’s ability to lower iron’s melting point, enabling low-temperature sintering. Phosphorus also improves key magnetic properties such as permeability, resistivity, and remanence while reducing coercivity, porosity, and magnetic losses. These enhancements make iron-phosphorus alloys ideal for high-performance EV motor components. |