This project will demonstrate breakthrough construction and performance of high-efficiency variable-speed machines based on permanent magnet assisted synchronous reluctance motors using…

The Department of Energy Office of Energy Efficiency and Renewable Energy awarded a $1.637 million Cooperative Agreement to ABB Inc., U.S. Research Center Division on July 1, 2026 under the Conservation Research and Development program (CFDA 81.086).

ABB will demonstrate construction and performance of high-efficiency variable-speed permanent magnet assisted synchronous reluctance motors (PMASR) using manganese-bismuth polymer bonded magnets as a rare-earth-free alternative. The project delivers a 22.4 kilowatt, four-pole industrial general-purpose motor operating at 1,800 RPM with minimum efficiency of 95.5 percent; a 100 kilowatt peak power, 18,000 RPM PMASR traction machine; development of mechanically stable manganese-bismuth polymer bonded permanent magnets with specified magnetic properties; manufacturing strategy for industrial production using compression molding; and market transformation planning including cost targets and life cycle assessment. The work targets utilization of North American mineral supply chains, particularly bismuth, to bridge the performance-cost gap between hard ferrites and rare-earth permanent magnets in industrial and traction applications, and to enable future carbon emission reductions in motors responsible for over 40 percent of global electricity consumption and transportation sectors.

Performance occurs in Raleigh, North Carolina from July 1, 2026 through June 30, 2028. The obligated amount is $1,637,800.

This project will demonstrate breakthrough construction and performance of high-efficiency variable-speed machines based on permanent magnet assisted synchronous reluctance motors using manganese-bismuth (MN-BI) polymer bonded magnets. The combination of new rotor design and manufacturing processes with the new magnet material will enable efficiency as high as rare-earth-magnet-based motors at costs comparative to induction or ferrite-based motors. The proposed solution comprises: 1. 22.4KW, 4-pole, industrial general purpose, pmasr (permanent magnet assisted synchronous motor) motor to operate at 1800 RPM with a minimum efficiency of 95.5% using MN-BI polymer bonded PM. 2. 100KW peak power, 18000 RPM pmasr traction machine using MN-BI polymer bonded PM. 3. Development of a mechanically stable MN-BI polymer bonded PM with BR = 0.30 t at room temperature and HCJ = 1600 KA/m at 125OC. 4. Manufacturing strategy for industrial PM production using compression molding. 5. Market transformation plan including cost targets and life cycle assessment targeted benefits of this project are 1. Utilize (US-north american) mineral supply-chain and assess resources availability (mainly BI, with currently no major use in the motor industry), providing high-aggregated value supply chain diversification; 2. Demonstrate first non-RE magnet bridging performance-cost GAP between hard ferrites and RE PM in industrial general purpose and traction motors.; 3. Determine capital and operating expenses data for manufacturing of MN-BI polymer bonded PM technology.; and 4. Enable future reductions in CO2 emission of pmasr motor construction (compared to those using RE-based PM) and operation for industrial applications, responsible for over 40% of the world electricity consumption, and from the highest polluting transportation sector with 1,852 MMT of CO2 in the US in 2022. Development will include 2-4 rotors targeting industrial general purpose industrial applications and one traction motor using PM compression molding. Task details follow. Year 1 (BP-1): will focus on parallel activities related to rotor design, rotor manufacturing, materials and technical-economic analysis. Deliverables from the first budget period include: (a) MN-BI powder with physical features for PM production via compression molding; (b) compression molded MN-BI bonded PM at least "good" as per acceptance classification table below (from technical volume, table 3); (c) electromagnetic and mechanical lamination design for an industrial, general purpose rotor; (d) industrial rotor construction and test utilizing compression molded MN-BI polymer bonded PM; (e) electromagnetic and mechanical lamination design for traction rotor prototype. (f) test data on MN-BI polymer bonded PM physical and chemical stability; (g) test data collected from MN-BI rotors; (h) supply chain considerations for industrialization of MN-BI polymer bonded PM; (i) techno-economic analysis for industrial, general purpose motor; and (j) life cycle assessment of MN-BI polymer bonded PM.