Bachelor/Master Thesis (m/f/d) – Impact of Manufacturing Processes on E-Steel Magnetic Performance

We are the movers of the world and the makers of the future.

As the German subsidiary of the Ford Motor Company, Ford-Werke GmbH has been successfully operating in the automotive industry for over 100 years. We are the movers of today and the makers of the future, working together to build a better world. As a modern mobility company, we are always ready for tomorrow. Around 12,000 employees are already contributing to this mission.

The Advanced Manufacturing organization in Cologne is at the forefront of Ford’s electrification strategy. We bridge the gap between product development and large-scale production, ensuring that our next-generation electric powertrains achieve peak efficiency and performance.

Qualifications

Your Profile

• Education: Currently enrolled in a Bachelor’s or Master’s degree program in Material Science, Electrical Engineering, Mechanical Engineering, Physics, or a related technical field.
• Technical Interest: Strong interest in electromagnetism, electric drive units, and material behavior under manufacturing influences.
• Lab Affinity: Willingness and ability to work hands-on in a laboratory environment.
• Analytical Skills: A structured approach to experimental setups and the ability to interpret complex data sets.
• Language: Good English skills are required (technical documentation); German is a plus for coordination within the local lab teams.
• Location: Ability to work on-site in Cologne to access internal laboratory infrastructure.

What We Offer – Why Ford?

• Unique Infrastructure: Gain hands-on experience in our Central Lab with access to specialized equipment not typically available in standard university environments.
• Cutting-Edge Technology: Work with bespoke rotor/stator testers and evaluate real-world components (lamellae) rather than just theoretical models.
• Expert Mentoring: Receive intensive guidance from experienced engineers in the Advanced Manufacturing and Materials team.
• Impact: Your research will directly contribute to the optimization of Ford’s future electric vehicle powertrains.

Location: Cologne (Niehl), Germany Duration: 6 months (standard thesis period)

Ford is committed to diversity and equal opportunity for all and opposes any form of discrimination or harassment based on gender, marital status, family situation, ethnic origin, nationality, disability, sexual orientation, religion or belief, gender identity, age, or caregiving responsibilities.

Your Responsibilities

• Research & Methodology: Investigate the influence of manufacturing-induced stresses and processing techniques (e.g., cutting, stacking) on the magnetic properties of electrical steel.
• In-depth Material Characterization: Conduct comprehensive analysis in our Central Lab, utilizing specialized equipment for optical, chemical, and mechanical characterization of e-steels.
• Electromagnetic Testing: Evaluate magnetic performance (e.g., core losses, permeability) using bespoke rotor/stator testers.
• Scaling Analysis: Perform comparative studies across different scales—from coupon-level samples to real motor lamellae.
• Data Correlation: Analyze the relationship between manufacturing parameters and electromagnetic degradation to provide actionable insights for e-motor production.
• Thesis Documentation: Formulate your findings into a high-quality Bachelor or Master thesis.