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Research on Joining High Pressure Die Casting Parts by Self-Pierce Riveting (SPR) using Ring-Groove Die Comparing to Heat Treatment Method

Bollhoff Inc.-Xuzhe Zhao
Chang’an University-Dean Meng
  • Technical Paper
  • 2020-01-0222
To be published on 2020-04-14 by SAE International in United States
Nowadays, the increasing number of structural high pressure die casting (HPDC) aluminum parts need to be joined with high strength steel (HSS) parts in order to reduce the weight of vehicle for fuel-economy considerations. Self-Pierce Riveting (SPR) has become one of the strongest mechanical joining solutions used in automotive industry for the past several decades. Joining HPDC parts with HSS parts can potentially cause joint quality issues, such as joint button cracks, low corrosion resistance and low joint strength. The appropriate heat treatment will be suggested to improve SPR joint quality in terms of crack reduction. But the heat treatment can also result in the blister issue and extra time and cost consumption for HPDC parts. The relationship between the microstructure of HPDC material before and after heat treatment with the joint quality is going to be investigated and discussed for interpretation of cracks initiation and propagation during riveting. The SPR joint quality will be evaluated based on interlock distance, the minimum remaining thickness (Tmin), shear strength etc. Instead of using heat treatment method, the…
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Design Consideration for Lightweighting With Ductile Iron Castings

Skuld LLC-Sarah Jordan, Mark DeBruin
Worcester Polytechnic Institute-Christopher Brown, Hudson Gasvoda
  • Technical Paper
  • 2020-01-0656
To be published on 2020-04-14 by SAE International in United States
There are opportunities for lightweighting with ductile iron castings. Current research shows ductile iron castings free of massive carbides can be achieved at under 2 mm (0.080”) through alloying or process changes which means that significant weight reductions are possible. In fact for aluminum components over 0.250” thick ductile iron may provide lightweighting opportunities at a cost savings. However, the conventional guidelines for casting design are inadequate when using ductile iron at dimensions less than the typical machine stock. This paper will discuss the current research on thin walled ductile iron, when it is superior to aluminum, design considerations, and current DOE SBIR funded research efforts to address these inadequacies.
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Electrical Heated Epoxy Tool for Rotational Molding Application

John Deere India Pvt., Ltd.-Sorna Rajendran Gandhi, Amit S Patil
  • Technical Paper
  • 2020-01-0234
To be published on 2020-04-14 by SAE International in United States
The conventional method of making rotational molding part is by heating the cast aluminum mold or sheet metal mold by hot air medium which has its own limitation on energy loss, the other means is by direct heat and cold of mold by passing hot oil/water in the mold to have better energy efficiency but leakage and safety problems associated with pumping pressurized hot oil / Water. There is no solution available for prototyping rotational molding parts using design intended material. The current practice of prototyping with conventional method is expensive and time-consuming. In this work, a simple method is presented to produce a rotational molded part with breakthrough in mold construction, which is Composite Mold Technology (CMT) with glass fiber reinforced epoxy resin built-in with electrical heaters. Project focuses is on proving CMT in comparison with the current production method. CMT reduce the cost by 90% and time to build Protomold by 30%. This electrical heated CMT can be used for new product development (NPD) and very low volume production as the cycle time of the part development was observed very high and life mold is yet to be tested. Deeper study of the life…
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Microstructure-Fatigue Property Relationships for Cast Irons

National Research Council (Canada)-Xijia Wu
  • Technical Paper
  • 2020-01-0187
To be published on 2020-04-14 by SAE International in United States
Cast irons are widely used for combustion engine/exhaust system applications, not only because they are less expensive but also because they offer some attractive properties such as good thermal conductivity, relatively high specific yield strength, and good oxidation resistance. Cast irons can be made with a wide variety of microstructures containing either flake-like graphite (FG), nodular graphite (NG) or vermicular graphite (VG), or mixing of the above, which control their mechanical and fatigue properties. In this paper, a microstructure-fatigue property relationship model is developed, combining the Tanaka-Mura-Wu’s fatigue crack nucleation model with Eshelby’s solution for materials containing ellipsoidal inclusions. This applies to cast irons considering its microstructural graphite characters (shape, size, elastic modulus and Poisson’s ratio). This model is used to analyse ductile cast iron (DCI) with nodular graphite (NG) microstructure, grey cast iron (GCI) with flake-like graphite (FG) microstructure, and compacted graphite iron (CGI) with vermicular graphite (VG) microstructure. Excellent agreement is found between the model prediction and the experimental data or the Coffin-Manson-Basquin correlations at room temperature. Further development will be to incorporate…
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Advances in Drilling with PCD (Polycrystalline Diamond)

Facet Precision Tool GmbH-Jeremy Bunting, John Bunting
  • Technical Paper
  • 2020-01-0035
Published 2020-03-10 by SAE International in United States
PCD properties were optimized to drill stacks of CFRP/Ti using an accelerated wear test milling gray cast iron. The optimized PCD was then used to prepare PCD drills. Tests were made to determine the best drilling conditions for the optimized PCD. The results yielded a significant improvement in cycle times as compared to earlier studies using PCD drills. Notched PCD cutting edges were found to eliminate oversizing of the CFRP near the interface of the two materials.
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Aluminum Alloy, Castings 5.0Si - 1.2Cu - 0.50Mg (C355.0-T6) Solution and Precipitation Heat Treated

AMS D Nonferrous Alloys Committee
  • Aerospace Material Specification
  • AMS4215J
  • Current
Published 2020-02-17 by SAE International in United States
This specification covers an aluminum alloy in the form of sand, permanent mold, composite mold, and investment castings.
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Automotive Pipe, Filler, and Drain Plugs

Air Brake Tubing and Tube Ftg Committee
  • Ground Vehicle Standard
  • J531_202002
  • Current
Published 2020-02-03 by SAE International in United States
This SAE Standard includes complete general and dimensional specifications for those types of pipe, filler, and drain plugs (shown in Figures 1 to 6 and Tables 1 to 4) commonly used in automotive and related industrial applications.
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Characterization of Friction Stir Processed Aluminum-Graphene Nanoplatelets Composites

SAE International Journal of Materials and Manufacturing

Sree Vidyanikethan Engineering College, India-P. Bhanu Prakash, P.C. Krishnamachary, K.C. Varaprasad
  • Journal Article
  • 05-13-02-0007
Published 2020-01-23 by SAE International in United States
The present study deals with the investigation on microstructural and mechanical properties of friction stir processed (FSPed) pure Aluminum (Al)-Graphene Nanoplatelets (GNPs) composites. Composite specimens such as castings were made by blending 0.5 wt.%, 1.0 wt.%, 1.5 wt.%, and 2.0 wt.% of GNPs in pure Al matrix using the ultrasonic-assisted stir casting technique (UASCT). Also for enhancement of mechanical properties via grain refinement the friction stir processing (FSP) has been employed, as well as mechanical properties like tensile strength and microhardness were evaluated. Moreover, the microstructural analysis were done using Scanning Electron Microscope (SEM), Field Emission Scanning Electron Microscope (FESEM), transmission electron microscopy (TEM), and X-Ray Diffraction (XRD) examination were also performed for inspecting the changes occurred during synthesis of the fabricated composites after FSP. After FSP, the experimental studies exposed that a uniform plastic deformation of GNPs in the pure Al matrix was achieved with less porosity that is leading to increment in mechanical properties with 11.26% enhancement in tensile strength and 12.17% enhancement in microhardness and thereby proves its potential for diverse engineering…
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Determination of Delta Ferrite Content

AMS F Corrosion Heat Resistant Alloys Committee
  • Aerospace Material Specification
  • AMS2315H
  • Current
Published 2020-01-13 by SAE International in United States
This specification covers two methods for determining the percentage of delta ferrite in steels and other iron alloys. When applicable, this specification will be invoked by the material specification.
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SUPPLIER EYE

Automotive Engineering: January/February 2020

  • Magazine Article
  • 20AUTP02_07
Published 2020-01-01 by SAE International in United States

Sustaining business in the 2020s

Does your company have a sustainable business model for the 2020s? The disruptive realities of Electrification and Automated Driving will only accelerate during this decade, bringing pressures unimaginable to suppliers in the last few cycles. Recent bankruptcies in the stamping and casting sectors as well as re-sourcing actions in other areas were driven by unfavorable product mix, exposure to tariffs and labor disruptions, a high cadence of product launches and structural shifts within the industry.

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