High-performance motor and generator laminations play a vital role in mission-critical aerospace applications and high-performance mil-spec defense systems. By specializing in precision stamping and NADCAP-certified annealing, Thomson Lamination Company (TLC) delivers magnetic components that exceed the performance limits of standard electrical steel.
This post examines how Hiperco 50 laminations optimize efficiency at high electrical frequencies and support the stringent weight constraints of unmanned aerial vehicles (UAVs) and electric aircraft.
When motor size and weight are strictly constrained by airframe or missile payload requirements, conventional electrical steel ceases to be a viable lamination material. The physical limits of its saturation magnetization force engineers to upsize the motor core to achieve targeted power outputs. This structural expansion inevitably increases system weight.
For applications where every gram affects mission range and payload capacity, cobalt-iron motor laminations made from Hiperco 50 alloy resolve this conflict by maximizing power density without increasing the footprint.
What is Hiperco 50? Understanding These High-Saturation Laminations
To solve the core saturation limitations of silicon steel, engineers turn to advanced metallurgy. Hiperco 50 is an iron-cobalt-vanadium soft magnetic alloy developed and trademarked by Carpenter Technology Corporation. Its composition is approximately 49% cobalt, 49% iron, and 2% vanadium. Trace niobium is often added to refine grains during mill processing and final heat treatment.
The critical metric for this material is its saturation magnetization: 24 kilogauss (2.4 T). This represents the highest magnetic saturation of any commercially available soft magnetic alloy. For comparison, conventional non-oriented electrical steel saturates around 19–20 kilogauss (1.9–2.0 T). The gap between those two values drives the lamination material selection decision in weight-critical applications.
At equivalent motor power output, cobalt-iron motor laminations in Hiperco 50 enable engineers to design a smaller, lighter core. In a platform where power generation systems compete for every cubic inch of space, this reduction in lamination stack size has measurable effects on the entire power system architecture.
Superior Permeability and Low Core Loss at High Frequencies
High saturation magnetization attracts the most attention, but permeability and core-loss performance are equally important in high-speed aerospace motor designs. Hiperco 50 laminations exhibit high DC maximum permeability and a low coercive force of approximately 0.4 Oe (32 A/m). Low coercivity means the material magnetizes and demagnetizes rapidly with low energy loss per cycle. In generators and actuators operating at elevated speeds, this becomes a significant efficiency factor.
Core loss in lamination stacks has two components: hysteresis loss and eddy current loss. Both climb as the electrical frequency increases. When properly annealed in a controlled protective atmosphere or vacuum environment, Hiperco 50 exhibits lower core loss than comparable electrical steel grades at frequencies relevant to aerospace motor operation.
Annealing protocol is a critical variable. The magnetic properties depend directly on the quality of the heat treatment. Final anneal conditions, such as temperature profile, atmosphere control, and thermal cycling, determine the crystallographic order in the alloy. For defense and aerospace applications, NADCAP-certified annealing is the established compliance standard for this material.
Future Applications: From UAVs to More Electric Aircraft (MEA)
The aerospace industry’s trajectory toward More Electric Aircraft (MEA) architectures replaces pneumatic and hydraulic systems with electrical actuation and power generation. Each system that converts to electrical operation adds motor and generator load to the airframe. Higher motor count under tighter weight budgets pushes lamination material selection further toward cobalt-iron alloys.
UAV programs accelerate this trend. Unmanned platforms operate under weight constraints that manned aircraft don’t face with the same intensity.
Aerospace and defense engineers specify cobalt-iron alloys across several critical platforms:
- Electric propulsion motors. These systems power Medium-Altitude Long-Endurance (MALE) UAVs, in which weight reduction directly extends flight endurance.
- Electro-hydraulic actuators. These units drive primary flight control surfaces on high-performance combat aircraft.
- Ram air turbines. These assemblies serve as emergency power generation units during in-flight power loss scenarios.
The material’s combination of thermal stability, mechanical strength-to-weight ratio, and magnetic performance also positions it for directed-energy and electromagnetic systems in defense applications.
Hiperco 50 vs. IMPHY® vs. VACOFLUX®
Defense applications typically specify Hiperco 50 because of its ITAR/DFARS traceability and military qualification history. Commercial aerospace programs may also use two European alternatives with equivalent 49% cobalt-iron-vanadium performance: Aperam’s IMPHY® SUPRA 50 and Vacuumschmelze’s VACOFLUX®/VACODUR®.
The key factor is compliance. Hiperco 50 fits programs requiring domestic sourcing and NADCAP-certified processing, while IMPHY® and VACOFLUX®/VACODUR® offer alternatives when sourcing flexibility is allowed.
Partner with TLC for Precision Hiperco 50 Lamination Manufacturing
Thomson Lamination Company has worked with cobalt iron motor laminations, including Hiperco 50 laminations, for decades across aerospace, defense, and medical programs. Our in-house capabilities span precision motor lamination stamping from cold-rolled strip stock, NADCAP-certified controlled-atmosphere annealing, and lamination stack assembly. We maintain full compliance with AS9100, ISO 9001:2015, ITAR, and DFARS.
Design engineers specifying Hiperco 50 for a new program benefit from early supplier involvement. Material traceability, anneal qualification, and tolerance stack-up requirements for thin-gauge cobalt-iron strip affect downstream manufacturability. We work with engineering teams during the design phase to surface those issues before they become production problems.
For early-stage programs, TLC also offers lamination prototyping services and support from engineers experienced in tool design and fabrication.
If your program requires cobalt iron motor laminations or a Hiperco 50 lamination stack prototype, contact our team or request a quote to discuss your specifications.
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