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The powertrain electrification is currently not only taking place in public road mobility vehicles, but is also making its way to the racetrack, where it’s driving innovation for developments that will later be used in series production vehicles. The current development focus for electric vehicles is the balance between driving power, range and weight, which is given even greater weighting in racing. To redefine the current limits, IAV developed a complete e-powertrain for a racing MX motorcycle and integrated it into a real drivable demonstrator bike. The unique selling point is the innovative direct phase-change cooling (PCC) of the three-phase e-motor and its power electronics, which enables significantly increased continuous power (Pe = 40 kW from 7,000 rpm to 9,000 rpm) without thermal power reduction. The drive unit is powered by a replaceable Lithium-Ion round cell battery (Ubat,max = 370V) with an energy storage capacity of Ebat = 5 kWh.

One key factor of a hybrid electric vehicle (HEV) is a maximized brake thermal efficiency (BTE) of the internal combustion engine (ICE). The new gasoline engine called NA16 is fully developed, tested and a high efficiency engine which is equipped with Phase Change Cooling (PCC) technology, low friction components (e.g. roller bearings), low pressure EGR and a high compression ratio combustion process. It operates with the optimal indicated specific fuel consumption (ISFC) in an engine power range from Peng =20-35 kW to show the overall potential of a bio- fuel (net zero CO2) compatible plug in hybrid electric powertrain. In addition, the goal was to reduce friction losses not only in the area of the ISFC best point but also in cold-start operation, which represents an additional challenge. The engine is also characterized by high EGR compatibility and/or lean combustion process, which is possible by the conversion to the PCC system.

High speed pulse welding creates a solid state weld between Powder Metallurgy materials (P/M) and to wrought materials. The fast weld pulse process is compatible with and advantageous to P/M component welding. This paper describes seven P/M alloys welded to 1010 sheet metal coupons. The carbon content and density are increased in seven of the alloys creating 37 welded material combinations. Carbon levels to 0.8 % were welded with densities of 6.6, 6.8, and 7.0 gram per cc. Each P/M group was evaluated by optimizing the weld schedule, then making specimen for strength determinations. Increasing density, carbon and alloy improved assembly strength.