Electric vehicles have become a regular sight on highways across the U.S., and electrification is being adopted in more industries and communities every year, but there are still opportunities for the technology to become more accessible, sustainable, and safe. Engineers at Marquette are working to solve problems with superelectric power, expand its use to include more applications, and reduce its reliance on unsustainable materials that are in short supply.
Dr. Ayman Al-Rifai is leading these efforts at Marquette, making Milwaukee a major contributor to the planet's electric future. As the Thomas and Susanna M. Werner Professor of Safe and Renewable Energy Systems and professor of electrical and computer engineering at the Opus College of Engineering, Al-Rifai currently leads two major DOE grants that will shape the future of electric vehicles.
In one of the projects, Al-Rifai and his collaborators are working on developing an electric powertrain to operate space propulsion for hybrid and electric aircraft. Electric aircraft are not yet widespread, but a lightweight engine with enough power for air travel could be a game-changer for airlines, the supply chain, travelers and the environment. Partners include the National Renewable Energy Laboratory, Florida State University, and the Raytheon Technologies Research Center.
In another project, Al-Rifai is helping to reduce reliance on heavy rare earth materials for electric cars – a material that is in limited supply and largely produced by China. Reducing or eliminating this dependence would reshape how EVs are manufactured and mitigate potential global monopolies on the technology. Partners include Virginia Polytechnic Institute and State University, General Motors, Neuromagnetics and the National Renewable Energy Laboratory.
In this Q&A, Dr. Al-Rifai discusses the latest developments in his work and what he sees for 2024 and beyond.
You and your collaborators have been working on these problems for a few years. Can you share where you are in the process and any milestones so far?
We are currently in the second phase of our Department of Energy project focused on electric motors for spacecraft propulsion. We have completed our conceptual design and initial testing and are now building a complete 250 kilowatt system that we aim to test in the summer of 2024. Our work has received positive reviews from the Department of Energy, and we are excited to move forward with our initial design phase.
We are also making important progress on our Department of Energy project focused on developing low-cost electric motors that eliminate heavy rare earths. Our teams are now focused on building a full-scale prototype of the engine. This will be an intermediate prototype so we can incorporate iron nitride (FeN) magnets developed by our industry partner, Niron Magnets in Minneapolis. Meanwhile, our collaborators at Virginia Tech will also build a full-scale prototype of the new low-cost power inverter.
We are keen to further develop this technology until it becomes a reality for the transportation industry and, ultimately, the public.
What trends do you see in the United States and globally regarding electricity?
Interest and growth in electrification is as high as ever and I expect this to continue for the foreseeable future. The government continues to make significant investments in this area, and we are seeing a high level of activity and innovation within both industry and academia. It's great for Marquette to be at the forefront of this technology, and to have great collaborators joining us. It has now become a major area of interest across disciplines, and there are many applications for electrification that are now being explored.
As your projects continue and the field evolves, what can the average citizen expect to change in their daily lives?
Renewable energy will continue to penetrate the residential and commercial sectors, and I expect consumers will begin to have a greater understanding of the technology beyond its novelty. We will see more electric cars on the road and more infrastructure to support charging and maintenance.
I also expect that we will see more adoption of hybrid and electric aircraft. Hybrid aircraft could change the consumer experience with both airlines and airport infrastructure, and fully electric aircraft will likely be used for shorter distance travel or even unmanned aircraft.
More and more of your neighbors will be thinking about purchasing an electric car, and it's not just engineers and technicians who will be familiar with it.
What motivates you to lead this business and move this technology forward?
The technological opportunity here is incredible. The performance targets for these proposed technologies could double or triple what is considered “state of the art” today. For any researcher, this is very challenging but also very exciting because it opens doors to push boundaries and develop very different and new techniques. As an engineer and problem solver, it's impossible not to be excited about this work every step of the way.
As you look to 2024 and beyond, what new problems, opportunities or factors will occur?
Technology is advancing rapidly and has a bright future, but it depends on continued support from the government. It also depends on continued public support and industry commitment to commercialize new advanced technologies. The goal is to get this technology out of the lab, and I'm grateful to the Department of Energy, our collaborators, and the broader field for sharing this vision.
