Jaydip Das of Carpenter Technology's CWIEME Berlin, CWIEME Central talk

1. Motors Re-imagined: Soft Magnetic Solutions to Enhance Efficiency
Carpenter Technology Corporation, USA

2. 2
Unique CRS Soft-magnetic Alloys: Strips, Powders, Bars
CRS high induction and permeability
Soft-magnetics:
Unique combinations of
• high induction/permeability and low loss
• High strength and high induction
• High corrosion resistance and induction
• Tailored material properties, dimensions
• 260+ high performance alloy
grades
• 127 years of innovation in
specialty alloys
• $1.8B sales (2016)

3. 3
Applications: Advanced Soft Magnetic Metal Solutions
Wide range of applications in Automotive, Consumer, Medical,
Aerospace/Defense, Energy, Communications industry
• Motors, generators
• Inductors, chokes, transformers, inverter/converters
• Chargers, wireless chargers
• Shielding, sensors, speakers
• Actuators, fuel injectors
CRS solutions help shielding,
power management,
charging in Consumer Electronics
Our motor material solutions help to
improve motor power density, efficiency for
Electric Vehicles (EV), Appliances, consumer
electronics etc.
Our advanced
solutions help saving
15-30% space with
increase the aero
plane generators
CRS high-induction
materials solutions help to
improve speaker
power, miniaturization.
Electrical Steel Hypocore Hiperco50A Electrical Steel Hypocore Hiperco50A
Current Design Modeled Modeled Current Design Modeled Modeled
s) 84 92 101 210 231 252
(N m) 280 297 342 430 456 525
ec) 9.9 9.3 8.1 5.5 5.4 4.5
mph) 93 93 93 130 130 130
k (kWh) 24 24 24 60 60 60
100 mile range passenger EV 200 mile range passenger EV
Electrical Steel Hypocore Hiperco50A Electrical Steel Hypocore Hi
Current Design Modeled Modeled Current Design Modeled M
Range (miles) 84 92 101 210 231
Max torque (N m) 280 297 342 430 456
0-60 Mph (Sec) 9.9 9.3 8.1 5.5 5.4
Top speed (mph) 93 93 93 130 130
Battery pack (kWh) 24 24 24 60 60
100 mile range passenger EV 200 mile range passenger EV

4. 4
Motor Solutions: Carpenter Materials Outperform Other Alloys
BH Curve Saturation Induction vs Core Loss
Hiperco50A®
Hypocore™
The highest induction alloy in the world
Alloy with a unique combination of high induction and low loss
Alloy Performance Comparison
CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of
Carpenter Technology Corporation
Hiperco27® High induction with higher thermal conductivity

5. 5
Carpenter Alloys can be used in both Stator and Rotor
Aerospace motor/generator industry has been using this technology for several decades
CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of
Carpenter Technology Corporation
Same Carpenter alloy can be heat treated
differently to achieve low loss for stator
and high mechanical strength for rotor
application needs
For Stator
After stamping
Heat treat higher T
For Rotor
After stamping
Heat treat lower T
Material Bs (T)
Hiperco50A 2.4
Hiperco50 2.4
Hiperco50HS 2.4
Hypocore 2.1
Nimark300 1.7

6. 6
Increased torque and efficiency means higher motor power density and lower loss
Carpenter Alloys Provide Higher Torque and Efficiency
Permanent Magnet (PM) Motor Torque vs. speed simulation profile
Hiperco 50A (0.15mm)
Hiperco 27 (0.10mm)
Hypocore (0.125mm)
Elec. steel (0.125mm)
Elec. steel (0.35mm)
CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of
Carpenter Technology Corporation
Hiperco50A
Electrical Steel
Study for PM Motor design close to
passenger BEV 100-200miles
Stator only

7. 7
Carpenter Alloys Improve Motor Power Density
CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of
Carpenter Technology Corporation
Higher torque and lower losses help to
improve motor power density
Higher torque from higher induction
Electrical steel
Hypocore
Hiperco27
Hiperco50A
Stator only
Lower loss from thinner, better strips
1/3
loss
Higher continuous power
20%

8. 8
Carpenter Alloys Help to Save Power
CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of
Carpenter Technology Corporation
8-10% current saving to achieve
similar torque for Hiperco50A
15-20% lower copper losses
for Hiperco50A
Hiperco50A motors can offer significant power saving
74%
Vs. M19
26% lower total loss for Hiperco50A

9. 9
Carpenter Alloys Help in Motor Size Reduction
Results in about 7%
power saving for this
specific design.
CRS materials offer smaller motor with higher power density
Smaller Hiperco50 motor helps to
improve motor power density
Lower copper and iron losses for Hiperco motor

10. 10
EV Motors Run Significantly Cooler w CRS Materials
PM Motor Torque vs. speed profile
Stator Winding Temperatures1
Low Speed (0rpm) High Speed (15,000rpm)
1 Modeled for a permanent magnet motor with fixed current, 300A
Thermal conductivity
Hiperco 50A
Hiperco 27
Hypocore
Electrical steel
88% higher
Carpenter materials can help to improve 2x motor life, as well improve motor efficiency
Hiperco 27 has high thermal
conductivity.
A motor using CRS materials run
cooler which reduces drive current
and associated copper losses and
can extend motor life.
CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of
Carpenter Technology Corporation
20C
Lower T
15 - 60C
Lower T

11. 11
CRS materials open design options for high power, energy efficient, durable motors
CRS Materials Open up Options for EV/Motor Designers
Motor benefits
• Power Savings
• Cost saving
• Space saving
CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of
Carpenter Technology Corporation
Motor Power Savings from EV drive cycle
4-6% power
savings
12-20% power
savings
8-12% power
savings
Permanent Magnet Motor
Hiperco 50A (0.15mm)
Hiperco 27 (0.1mm)
Hypocore (0.125mm)
Electrical steel (0.35mm)
Higher Torque
10-22% for Hiperco 50A
8-13% Hiperco 27
3-6% for Hypocore
Improved Motor
Efficiency
Lower Fe/Cu loss
Motor design
freedom
Smaller motor
Improved life
Less heat generation
Simulated data

12. 12
Electric Vehicle, Permanent Magnet Motor Specs
Comparison PM Motor Specs using Carpenter magnetic materials
CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of
Carpenter Technology Corporation
Key Motor Benefits:
✓ High power density
✓ High torque density
✓ Higher efficiency
✓ Increased motor life
DC bus voltage: 450V
Max stator current (peak): 480A

13. 13
Electrical Steel Hypocore Hiperco50A Electrical Steel Hypocore Hiperco50A
Current Design Modeled Modeled Current Design Modeled Modeled
Range (miles) 84 90 101 210 225 252
Max torque (N m) 280 297 342 430 456 525
0-60 Mph (Sec) 9.9 9.3 8.1 5.5 5.4 4.5
Top speed (mph) 93 93 93 130 130 130
Battery pack (kWh) 24 24 24 60 60 60
Battery weight (kg) 300 300 300 540 540 540
Vehicle weight (kg) 1,500 1,500 1,500 2,090 2,090 2,090
100 mile range passenger EV 200 mile range passenger EV
Modeled up to 20% higher range, power density and torque. Motor parameter optimization can bring further gains.
Carpenter Alloys Drive EV Performance Gains
Carpenter’s unique soft-magnetic materials can increase EV motor torque and power
density, extending vehicle range and delivering faster acceleration.
1 2
1 The Nissan Leaf is used as the model for a 100 mile passenger electric vehicle.
2 The 200 mile passenger electric vehicle is modeled from an approximation of a Tesla Model S based upon available vehicle and motor specifications.
Focus areas for
performance
improvements -
design models
~20% improvement
CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of
Carpenter Technology Corporation

14. 14
Electrical Steel Hypocore Hiperco50A Electrical Steel Hypocore Hiperco50A
Current Design Modeled Modeled Current Design Modeled Modeled
Range (miles) 100 100 100 300 300 300
Vehicle weight with
max. payload (kg)
20,000 20,000 20,000 36,160 36,160 36,160
Battery weight (kg) 5,500 5,115 4,400 11,800 10,974 9,440
Max. payload weight
(kg)
14,500 14,885 15,600 24,360 25,186 26,720
100 mile range commercial truck 300 mile range commercial truck
20,000
-10,000
16,200
Design Options to Improve EV Truck Economics
-10,000
20,000
10,000
0
3,190
6,300
-10,000
10,000
0
20,000
8,600
100 mile
range1
300 mile
range2
100 mile
range1
300 mile
range2
Motor cost increase
Battery cost savings
Net cost savings
Hypocore PM* Motor Hiperco50A PM* Motor
* PM motor (rotor + stator)
1 Cummins E-truck specs with 2 motors
per truck used as basis for modeling.
2 Tesla Semi specs with 4 motors per
truck used as the basis for modeling.
1
2
Larger payload capacity, faster charging and powertrain cost savings from smaller battery packs
Focus areas for
performance
improvements -
design models
9.7% larger payload capacity7.6% larger payload capacity
Hypocore™ savings across all ranges Hiperco® cost savings are significant
2 Modeling based upon $250kWh battery
cost and current alloy prices.
CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of
Carpenter Technology Corporation
Carpenter’s materials save powertrain cost, improve payload capacity.

15. 15
Cost Savings for Industrial Motors
1
Carpenter Hypocore can offer significant energy and cost saving for industrial motors
CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of
Carpenter Technology Corporation
Energy used by different
motor power type in USA
Source:
Industry Guide Book,
U.S. Dept. of Energy
Motors greater than 37kW use
more than 70% of energy
Hypocore PM motor cost savings
Motor cost increase
Electricity cost savings per year
Significant 5 yr. cost
benefit from Hypocore
5 yr. cost savings
Break even
@1 yr
Carpenter’s materials save
operations and maintenance cost.
Cost saving
@1 yr
2 Modeling based upon $0.1/kWh
electricity cost and current alloy prices.
Net cost saving@1yr

16. 16
Different Motor Applications
1
Applications that require size/weight reduction, higher power density and higher
efficiency are candidates for Carpenter motor materials.
Oil & Gas
(ESP Pumps)
Medical
(Home equipment, surgical devices)
Consumer Goods
(Vacuums, power tools, robots, etc.)
Consumer/Residential
(HVAC, Appliances)
Automotive (non-traction)
(20+ motors and actuators per vehicle)

17. 17
Stamping: The Preferred Stack Manufacturing Process
• Melt region at edges of laser and EDM cuts affects material properties and is the primary
contributor to decreased induction and increased losses
• Carpenter recommends notch stamping for prototyping
H (Oe)
B(kG)
Core Loss
5-35% increase in core losses @Laser, EDM
B vs. H
8-12% decrease in induction @Laser, EDM

18. 18
Stator and Rotor Stacks
CRS can offer finish stack with optimum magnetic property
Carpenter offers finished stacks with optimal magnetic properties for prototype and production
Stamping Annealing Stack Assembly
Index Notch Stamping Progressive Die Stamping
Progressive Die
Stamping with Interlock
Stack System
Lamination thickness* 0.002 – 0.014” 0.004 – 0.014” 0.010 – 0.014”
Stack assembly Bonding/gluing required Bonding/gluing required No bonding/gluing
Economical quantities Up to 10,000 laminations
10,000 – 1,000,000
laminations / part / year
> 1,000,000 laminations /
part / year
Recommendation Prototype and low volume Medium to high volume High volume
CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of
Carpenter Technology Corporation
* For Hiperco 50A

19. 19
Carpenter High Permeability and Corrosion Resistant Alloys
Best
Carpenter Chrome Core grades offer
good corrosion resistance w reasonable
magnetic properties
Fuel injector
Corrosion Resistant Magnetic Materials
High permeability, low loss materials
Iron-Nickel grades
Carpenter Iron-Nickel grades high permeability w
low loss making those attractive high speed, high
frequency applications
Stator,
Servo Motor
Speaker/hearing
aid driver
Chokes,
transformers
for Smart Grid

20. 20
Carpenter is Developing New Material Solutions
Significant motor power
saving at high speed for
CRS new alloy.
Lower stator losses
(Bs 1.8T)
CRS New
material
Useful for high speed motors, inductors, wireless charging, transformer applications
High induction/perm, high electrical resistivity, low loss alloy

21. 21
Carpenter Soft-magnetic Powders
Materials
D50
(μm)
True Density
(g/cc)
Saturation
Induction (T)
Coercivity
(±1 Oe)
Resistivity (µ
ohm-m)
Carpenter
amorphous
20-25 7.01 1.51 <10 1.3
Fe6Si D90 < 22 7.40 1.8 <13 0.8
Fe50Ni D90 < 10 8.17 1.53 <22 0.48
HyMu 800 15-25 8.70 0.87 <5 0.58
Sendust 15-20 6.80 0.81 <5 1
FeCo35 8.8 7.99 2.4 <40 0.4
FeCo50 8.6 8.13 2.32 <40 0.4
Nimark300 25-35 8.02 1.78 <5 0.4
430L D90 < 31 7.62 1.63 <25 0.6
Fe8Cr D90 < 7 7.72 1.91 <29 0.49
Typical Properties
✓ High perm
✓ Low loss
✓ Good induction
✓ High perm
✓ Reasonable loss
✓ Low loss
✓ High induction
✓ High strength
✓ Good induction

22. 22
Amorphous Powder Applications
Component Applications
Thin Film Wire Wound
▪ Miniaturization
▪ Complicated 3D shapes
▪ Less signal noise/cross-talk
▪ Higher frequencies
▪ Power consumption
Amorphous powders enable high performance power components for emerging device requirements
Power Inductors
Chokes
Cores
Device and Component Performance DriversCarpenter Amorphous Powder Benefits
▪ High induction
▪ High permeability
▪ Low core loss
▪ Ideal for multilayer designs
Metal Composites
Carpenter powders can be mixed with epoxy or
thermoplastic and cast to produce the 3D shaped
inductor component body
Molded composites
Wireless charging
Example composite
properties
(open to discussions for
further improvements)

23. 23
Permeability, Loss Improvement for Metal Composites
1. Optimize particle-particle contact/distance, driven by particle
morphology (sphere, flake etc), packing factor (small, big particle etc)
2. Optimize particle size, bigger size will decrease number of particle-
particle contact, will increase perm, but also loss increases
3. Optimize choice of particle material, Amorphous, HyMu, FeCo,
other powders, and/or combinations
4. Optimize insulation coating thickness
(Numberofparticle-
particlecontact)-1
Less #contacts@ spheres,
More contacts @flakes
PowderEpoxy
Drastic drop in perm w gap distance
Optimization of specific power shape, size can help to improve composite permeability, loss

24. 24
High Induction Powders for Metal Injection Molding (MIM)
Soft magnetic powders with high induction and
MIM processing may help to improve output
power, miniaturization, ease to achieve
complicated 3D shapes
Soft-
magneticCoil
MIM parts w high induction
1. Feedstock formulation,
2. Mold process parameters,
temperature, pressure, screw designs,
speed to achieve homogeneous mixing
3. Sinter conditions, temperature,
atmosphere to optimize the desired
diffusion and phase
Critical MIM parameters to
improve part properties
At. % Co
Fe-Co phase diagram
Intra-particle diffusion
Desired ordered
phase
Nishizawa et. al, ASM International 1990

25. 25
Additive Manufacturing and Soft Magnetics
Soft-magnetic additive parts can offer to unique application properties, save cost
Carpenter Technology is developing end-to-end soft-
magnetic solutions using additive manufacturing
▪ 10-70% weight reduction
▪ Lead time reduction: months to weeks
▪ Advanced material properties
▪ Improved fluid dynamics
▪ Internal complexity
▪ Lower component lifetime costs
▪ Unitization / consolidation of parts
▪ Digital product definition
▪ Replacement parts
▪ And others….
Example benefits
AM Tech Center, Reading, USA
Wide range of powder size Different additive technologies
Finished parts of different sizes, shapes, resolutions

26. 26
Summary: Applications Carpenter Soft Magnetic Solutions
Wide range of applications in Automotive, Consumer, Medical,
Aerospace/Defense, Energy, Communications industry
• Motors, generators
• Inductors, transformers, inverter/converters
• Chargers, wireless chargers
• Shielding, sensors, speakers
• Actuators, fuel injectors
CRS solutions help shielding,
power management,
charging in Consumer Electronics
Our motor material solutions help to improve
motor power density, efficiency for Electric Vehicles
(EV), Appliances, consumer electronics etc.
Our advanced
solutions help saving
15-30% space with
increase the aero
plane generators
CRS high-induction materials
solutions help to improve
speaker power, miniaturization.

27. 27
Carpenter – Your Most Preferred Technology Partner
Comprehensive alloy and product portfolio
consisting of the most powerful & efficient
soft magnetic alloy in the world1
R&D to full scale production, coupled
with Application Engineering support3
Serial Production Scalability
Finished stack2
CarTech, Hiperco, and Hypocore are registered trademarks of CRS Holdings, Inc., a subsidiary of
Carpenter Technology Corporation

28. APPENDIX
EV Motor Material Solutions

29. 29
Appendix | EV Motor and Drive Cycle Modeling
• Permanent (PM) and Induction Motor (IM) simulations
performed by Motor Design Ltd., using motor CAD
software. PM, IM motor design/responses close to Nissan
Leaf, Tesla S.
• Simulation comparisons obtained for different stator/rotor
materials for the same respective motor design.
• Car level 10 min. aggressive drive cycle considering city
and highway (US06 drive cycle).
• Active cooling. Coolant mixture of ethylene glycol, water;
flow rate 6.5liter/min.
• Battery/powertrain cost estimations obtained from EV,
Literature Review, International Council of Clean Energy,
2016.
Drive cycle Includes
vehicle model, drag,
powertrain
Vehicle speed estimated
with vehicle gear ratio,
wheelbase
PM (8 pole) IM (4 pole)