Overview of Amorphous Soft Magnetic Materials for Electric Vehicle Motors: Performance, Challenges, and Future Directions

Amorphous soft magnetic materials (AMMs) have demonstrated significant advantages in electric machines due to their low core losses, high permeability, high tensile strength, and superior energy efficiency at high operating frequencies. Despite these benefits, their adoption in electric vehicle (EV) motors remains limited. This review explores the key technological, economic, and industrial barriers preventing the widespread use of AMMs in EV applications. An overview of the AMM fundamentals, including the material composition, manufacturing processes, and recent advancements, is first presented. To quantitatively assess their potential in traction applications, a numerical study is conducted on two 5.5 kW synchronous reluctance machines with identical geometries, employing AMM and conventional silicon steel stators, respectively. The machines are compared in terms of electromagnetic torque and efficiency, highlighting the impact of AMM properties on machine performance. These results are discussed alongside the findings from the existing literature to evaluate the core loss reduction, electromagnetic behavior, mechanical robustness, and thermal considerations. Special attention is given to the emerging commercial applications of AMMs in EV motors, which have only recently begun to materialize. Finally, the study highlights the gap between academic research and industrial implementation and identifies critical research areas needed to accelerate AMM adoption.