Material Synergy and Efficiency Enhancement in Axial Flux PMSM: Influence of Magnet, Core and Conductor Combinations

This study investigates the material-dependent performance of an axial flux permanent magnet synchronous motor (AF-PMSM) through a ‎systematic evaluation of magnet, core, and conductor combinations. The analysis reveals that transitioning from ferrite to high-energy ‎NdFeB magnets significantly enhances efficiency, ranging from 74.58% to 85.91%, while concurrently increasing sensitivity to iron-core ‎losses. Employing low-loss core materials, particularly Hiperco50, markedly improves overall efficiency, underscoring the necessity of ‎advanced magnetic alloys in high-flux-density motor systems. Among the examined magnets, the advanced N55 grade NdFeB achieves the ‎highest efficiency (87.19%) and lowest loss, surpassing Alnico5 and SmCo24. Although SmCo24 offers superior thermal stability, its per-‎formance remains inferior to that of N55. Conductor analysis further reveals that silver windings yield the highest efficiency (88.03%) and ‎lowest total losses, slightly outperforming conventional copper at the expense of increased weight. Gold and aluminium conductors, by ‎contrast, exhibit reduced efficiency due to higher resistivity. The findings highlight the crucial interplay between magnet strength, core loss ‎characteristics, and conductor resistivity in determining overall AF-PMSM efficiency, providing valuable insight for the material optimiza-‎tion of traction motors in electric vehicle applications‎.