High Power-to-Weight Ratio Engines for Aerospace Manufactured by Cold Spray

PROJECT COST:

1 583 960 $

PRIMA CONTRIBUTION:

689 960 $

PROJECT DETAILS:

The decarbonization of the aviation sector necessitates a transition toward electrification. Achieving this objective will require the development of electric motors and generators with high power-to-weight ratios, capable of operating at elevated speeds and temperatures. Such demanding operating conditions render conventional electric machine architectures and the widespread use of NdFeB permanent magnets unsuitable. Consequently, the exploration of alternative materials and novel motor topologies becomes essential, along with a reassessment of conventional manufacturing methods to accommodate these emerging technologies.

This project aims to develop high power density motors for aerospace applications by pushing the limits of the cold spray process for the fabrication of electric machine rotors. The approach involves an innovative architecture based on materials capable of operating at elevated temperatures (~300 °C) without significant performance loss or rapid degradation. Candidate materials include samarium–cobalt + aluminum composites and/or copper-based alloys.

The project will strengthen Quebec’s expertise in cold spray additive manufacturing through collaboration between Polytechnique, the National Research Council (NRC), and Polycontrols. For Polycontrols—a Quebec-based SME specializing in cold spray technology—the new knowledge gained will provide a competitive edge in the rapidly growing electric transportation market. For Safran, the project offers opportunities to commercialize new aerospace motor products. Finally, for Altair, this collaboration represents an opportunity to expand and enhance the capabilities of its electric motor design software tools, supported by direct feedback from a multidisciplinary team.

More than seven students – including four doctoral candidates, two master’s students, and one postdoctoral researcher—will be trained in permanent magnet technology for aerospace, complex part manufacturing using cold spray, and innovative electric machine design.