Your Destination for Mobility Engineering Resources

This SAE Aerospace Information Report (AIR) has been written for individuals associated with ground level testing of turbofan and turbojet engines, and particularly for those who might be interested in investigating steady-state performance characteristics of a new test cell design or of proposed modifications to an existing test cell by means of numerical modeling and simulation. It is not the intent of this standard to provide specific test cell design recommendations, which are covered in the reference documentation.
EG-1E Gas Turbine Test Facilities and Equipment
Over the last few years, there has been an uptick in the exploration and implementation of aluminum high-pressure die casting (HPDC) mega-castings as replacements for conventional stamped steel parts in vehicles. This trend is expected to increase with common justifications, including claims of reduced costs and lower environmental impacts associated with the replacement of dozens of individual parts with a single casted piece, along with reduced demands on associated tooling and machinery. However, the data and literature to support these claims are limited and at times contradictory, with some studies showing increased costs and energy demands for mega-casting technologies. This study presents the results of a literature review and a gate-to-gate life cycle inventory (LCI) adapted from conventional HPDC aluminum casting unit processes that may be used to quantify potential life cycle global warming potential (GWP), cumulative energy demand (CED), and other environmental impacts of
Sebastian, BrandieBalzer, Russ
This study examines the aerodynamic performance of a wing section incorporating high-lift airfoils for use in a solar-powered Unmanned Aerial Vehicle (UAV) operating at low speeds. This paper evaluates the aerodynamic performance of a wing section integrated with high-lift airfoils for application in a solar-powered UAV. The primary objective is to simulate low-speed flight conditions representative of solar-powered UAV missions in order to obtain relevant aerodynamic parameters by adopting Eppler 387 and Selig 1223 airfoils. Experimental and Numerical simulations are performed over a range of angles of attack to systematically assess key aerodynamic coefficients, including the coefficient of lift (Cl), coefficient of drag (Cd), and coefficient of pressure (Cp) to sustain the flight physics and steady level flight. A scaled prototype of the wing section is experimentally evaluated in a low-subsonic wind tunnel to validate the computational results under low-speed operating conditions
D., LakshmananSwaminathan, Selvam
Improved energy efficiency and lower CO2 emissions are the two major drivers for the emergence of E-mobility. Growth of electric vehicles (EVs) has sustained ever since their introduction till 2020 and has substantially increased thereafter. EVs require specialized lubricants, which are different from conventional lubricants mainly due to the addition of new hardware technology including e-motor, inverter, battery, and new materials (copper windings, elastomers, plastic, and other materials). Lubricant when used in an advanced powertrain electric vehicle specifically in E-powertrains may encounter the e-motor and must deliver unique performance attributes such as optimal electrical properties, thermal management, and material compatibility apart from the traditional features including extreme pressure, friction performance, oxidation, and wear control. In the current study, we have investigated conventional GL5, manual transmission fluid (MTF), automatic transmission fluid (ATF), and
Katta, LakshmiSeth, SaritaSingh, SandeepBhardwaj, AnilArora, Ajay Kumar
Distributed drive electric vehicles (DDEVs) provide enhanced maneuverability through independent wheel torque control, but coordinating precise path tracking with lateral stability remains challenging under aggressive driving conditions. This paper presents a coordinated control strategy that integrates model predictive control (MPC) for path tracking with a proportional gain controller for stability regulation. The proposed framework adopts a hierarchical design. The path tracking control leverages MPC to compute front steering commands while accounting for vehicle dynamics and preview errors. The stability adjustment uses dual proportional gain controllers to generate an additional yaw moment, which is adaptively balanced through a phase plane coordination mechanism, enhancing yaw stability during path tracking. The generated yaw moment is subsequently distributed to individual in-wheel motors with an optimization torque allocation method, respecting tire force limitations. The
He, YangZhu, YuzhengGuo, RuixinZhu, YueyingXing, ChaoLiu, ShuangxiLin, Yier
This SAE Recommended Practice establishes uniform test procedures for friction based parking brake components used in conjunction with hydraulic service braked vehicles with a gross vehicle weight rating greater than 4500 kg (10 000 lb). The components covered in this document are the primary actuation and the foundation park brake. Various peripheral devices such as application dashboard switches or indicators are not included. These test procedures include the following: a Brake Related Tests 1 Brake Functional Performance 2 Brake Dynamic Torque Performance 3 Brake Corrosion Resistance 4 Brake Endurance with Torque 5 Brake Endurance without Torque 6 Vibration Resistance 7 Brake Ultimate Static Load 8 Brake Lining Wear Adjuster Function b Actuation Related Tests 1 Mechanical Actuator Functional Performance 2 Mechanical Actuator Endurance 3 Mechanical Actuator Quick Release 4 Mechanical Actuator Ultimate Load 5 Spring Apply Actuator Functional Performance 6 Spring Apply Actuator
Truck and Bus Hydraulic Brake Committee
E-25 General Standards for Aerospace and Propulsion Systems
Decarbonization efforts achieved through electrification in nonroad mobile machinery can realize a reduction in fuel consumption of more than 20%, thanks to concepts familiar to light-duty passenger vehicles. This case study compares the results of a hybrid-electric material handler to its conventional counterpart, utilizing machine-specific drive cycles presented in part one of this paper series. The hybrid prototype features an extended-range electric vehicle (EREV) powertrain that demonstrated substantial energy efficiency improvements. Specifically, there was a reduction in equivalent fuel consumption of 75% when operating in electric-only mode, and 33% when maintaining the battery by charging with an on-board generator. Together, the efficiency improvements can be extrapolated over a low-intensity, 8-h shift characterized by significant idle time and highly dynamic engine load for a 47% reduction in net energy consumption. Key technologies that led to this improvement included
Czarnecki, AlexanderGoodenough, BryantWorm, JeremyRobinette, DarrellLaTendresse, PhilWestman, JohnSubert, DavidHeath, MatthewKiefer, DylanBlack, Andrew
This SAE Aerospace Recommended Practice (ARP) establishes the overall component and system function guidelines and minimum performance levels for a TPMS. These guidelines include, but are not limited to: Design recommendations for system components, which: Monitor tire inflation Are located in/on the tire/wheel assembly, landing gear axle, and/or aircraft avionics compartment Recommended performance and safety guidelines for a TPMS.
A-5 Aerospace Landing Gear Systems Committee
The development of lightweight materials for use in aerospace and automotive applications is extremely significant. Magnesium (Mg)-based alloys and composites are good candidate materials from the perspective of low density, good specific strength, and abundance. The Mg-4Zn alloy is one such alloy, which is a lightweight, biocompatible, and eco-friendly Mg-based alloy. In spite of these advantages, there is a strong need and scope to improve its wear resistance and mechanical properties. Mg-4Zn nanocomposites with Si3N4 reinforcements (a biocompatible bioceramic) are hypothesized to possess superior properties. Microstructural analysis of the vacuum stir-cast nanocomposites confirms grain refinement and a consequent increase in microhardness with an increase in Si3N4 reinforcement wt.%. The addition of Si3N4 reinforcement to improve the properties of the Mg-4Zn alloy could introduce challenges in machining. To make products from the nanocomposites, machining them with minimal
N, AnandShaju, Tony MG, Nagamalleswara RaoD, BijulalK, Jayaprakash ReddyK, VijayanChaman, Joji J
Aerospace manufacturing operates within an intricate ecosystem where quality, compliance and traceability are critical to success. Conventional digital thread frameworks provide connectivity but remain largely passive, lacking the intelligence to autonomously manage complex non-conformities across the product lifecycle. This paper introduces an Agentic Digital Thread powered by Agentic AI, designed to transform non-conformity management into an adaptive, self-orchestrating system that actively drives decision-making and corrective actions [1, 4]. The proposed architecture employs a Master Agent to coordinate workflows and maintain end-to-end data continuity, while specialized Agents autonomously manage domain-specific tasks. In the pre-manufacturing phase, these agents proactively validate requirements, material conformity and process planning through integration with PLM, MES, ERP, QMS and supplier systems. In the post-manufacturing phase, the framework extends to concession
Veluri, SastryGopala Krishnan, Kannan
The study proposes the use of Carbon Fiber Reinforced Plastic (CFRP) sandwich composites configurations for structures interfacing cryogenic tankages. To address the design challenge posed by high thermal contractions in metallic tanks after cryogenic propellant filling, the study incorporates slits near the tank interfaces. Additionally, to minimize the transfer of cryogenic temperatures into these interfacing parts, the sandwich structure features interface end attachment made of thermally insulating Glass Fiber Reinforced Plastic (GFRP) material. Analytical and Finite Element (FE) studies were conducted on a typical cylindrical cryogenic intertank structure to demonstrate the proof of concept. These studies included analytical design using MATLAB based codes, parametric analyses with simplified shell element models and detailed 3D sector models using solid elements. The parametric studies assessed the effects of the number and dimensions of slits to achieve an optimal design, while
Bhalerao, Sandesh PopatGupta, Yogesh KumarMadhukumar, P.
This research investigates the fabrication and evaluation of Delrin (polyoxymethylene, POM) composites reinforcing 5-20 wt.% chopped ramie fiber (RF). The polymer composites were fabricated via the injection moulding technique. Glass transition temperature (Tg), thermal conductivity, Vicat softening temperature (VST), heat deflection temperature (HDT), melt flow index (MFI), and coefficient of linear thermal expansion (CLTE) were the various thermal characteristics of the sustainable composites that were systematically evaluated as per the ASTM standards. The addition of RF drastically altered the Delrin matrix's performance. Among the formulations, the composite with 15 wt.% RF had the best combination of properties: higher VST and HDT values, which provide greater dimensional stability at high temperatures; lower CLTE, resulting in less thermal expansion; comparatively better thermal conductivity; and improved heat dissipation. Eventually, there was a moderate drop in the MFI
S, ThirumalvalavanSenthilkumar, N.Selvarasu, S
The aerospace industry is undergoing a significant digital transformation in the way system requirements are defined, communicated, and managed. Major OEMs are moving towards fully model-based development processes, with plans to deliver requirements exclusively in the form of models. It is no longer sufficient to manage requirements using traditional document-based approaches; instead, organizations must adopt tools and processes that enable the consumption, interpretation, and implementation of model-based requirements. However, MBSE itself does not ensure that the requirements defined within the model are complete or consistent. Without rigorous validation techniques, even well-structured models can carry forward poorly defined or conflicting requirements — leading to errors that propagate throughout the development lifecycle. This work proposes an approach that integrates formal methods into MBSE workflows by enabling completeness and consistency checks of SysML-based requirements
Gupta, ChandanNakkeeran, Rupashree
Digital engineering practices in aerospace increasingly require closely connected and traceable analysis workflows rather than isolated finite element tasks. Traditional FEA methods remain effective, but they involve considerable manual effort during pre- processing and post-processing, making rapid iteration difficult. Finite Element Analysis of STructures (FEAST), an indigenous finite element analysis software developed by Vikram Sarabhai Space Centre (VSSC) ISRO, offers structural analysis capabilities through a command-based architecture, yet its manual operation limits its use in automated studies. This work develops a flexible scripting-driven framework that links geometry creation, load-case definition, solver execution, and result interpretation within a unified digital engineering pipeline. The framework automates repetitive tasks, incorporates Design of Experiments (DoE) for systematic parameter variation, and supports sensitivity and automation studies. Its performance is
Gupta, ShivangiT J, Raj ThilakP, Deepak
The purpose of this document is to provide a template and guidance for the preparation of an SAE International technical paper. This template is comprised of the entire document “How to Write a Technical Paper” so that authors have all information where needed. You can use this template by removing all the content, text, and other information and then can use the “Styles” available in MS Word®. The main styles used are Heading 1, Heading 2, Heading 3, List Ordered Numeric (for numbered lists), List Unordered (for bullet lists), Normal (for the body of the text), Figure (for figure captions), Title (for Table titles), and Normal Table (for table body). To use the Styles feature, you can highlight the copy, select the drop-down beside Styles, and select which style you want. Alternatively, you can select the correct Style first and then begin typing. SAE International does not restrict the number of pages for a technical paper, although the recommended length is 9-12 pages in a 2-column
Turaga, Vijay KumarAadi Gopalakrishna, PradeepVasudevan, Dinesh Babu
Trajectory optimization for reusable launch vehicles is a critical challenge in space mission design, aiming to determine fuel-efficient paths for spacecraft during ascent, hover, and descent phases. Minimizing fuel consumption not only enhances cost-effectiveness but also improves mission sustainability. The optimization process is governed by nonlinear orbital mechanics, gravitational perturbations, atmospheric drag, and operational constraints such as thrust limits and collision avoidance. These factors make the problem highly non-convex and discontinuous, posing significant difficulties for classical gradient-based approaches, which often fail to identify global optima. In this work, we formulate the trajectory optimization problem for a reusable rocket executing an ascent–hover–descent cycle. The vehicle must ascend to a specified target altitude, maintain a stable hover for a given duration, and then return to the launch site. The primary decision variable is the throttle control
Eswara Sai Kumar, KandulaSingh, UtkarshPohankar, PritamA, AnoopMaharana, PriyabrataLineswala, Rut
Model-based development (MBD) and Model-based Testing are critical for airborne software compliance with DO-178C and its supplement DO-331, which specifically addresses model-based approaches for software levels A through D. Traditional manual methods increase the documentation and validation burden, leading to inconsistent implementations across the project, and raise the risk of missed defects or gaps in compliance. This paper presents an automation framework designed to align with DO-331 objectives by leveraging fine-tuned large language models (LLM) to automate the generation of high-level textual requirements and low-level model-based requirements. From these, comprehensive test cases are automatically derived, covering normal, edge, mutation based, and dynamic scenarios to ensure a thorough validation of model behavior. Utilizing AI agent, the framework extracts requirements and key parameters from documentation, enabling automated specification analysis and test script
Lalchandani, TusharPurushothaman, KalaivaniJeppu, YoganandaVijaya Kumar, Shree HarshaNatarajan, Akilandeswari
Aerospace products operate within highly complex, safety-critical environments and endure extended lifecycles, often spanning decades. Sustaining their operational value requires rigorous management of Safety, Reliability, and Availability (SRA), while global Environmental, Social, and Governance (ESG) mandates demand parallel progress toward sustainability goals. This paper introduces an AI-driven strategy that integrates these dual imperatives—Sustenance Management and Sustainability Management—within a unified Product Lifecycle (PLC) framework. The proposed approach leverages Artificial Intelligence across five PLC phases: Generative Design, Detailed Design & Verification, Manufacturing & Industrialization, Operations & Maintenance, and End-of-Life Circularity. Anchored by a certified Digital Thread, this framework ensures seamless, auditable data flow from concept to disposal. Using Life-Limiting Parts (LLPs)—such as high-stress turbine discs—as a case study, the paper demonstrates
Srinivasan, KarthikG.V.V., Ravi KumarVaderahobli, Devaraja HollaBhate, UjwalVeluri, Sastry