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Aerospace & Defense Technology: December 2019

  • Magazine Issue
  • 19AERP12
Published 2019-11-28 by SAE International in United States
Engineered Solutions for Enclosure Sealing and InsulationTips for Reducing Error When Using Eddy Current Measuring TechniquesReducing the High Cost of TitaniumStreamlining Post-Processing in Additive ManufacturingSoftware-Defined Analog Filters: A Paradigm Shift in Radio Filter Performance and CapabilitySDR Interface for the NeXtRAD Multistatic Radar SystemElectrodeposition of Metal Matrix Composites and Materials Characterization for Thin-Film Solar Cells Metal matrix composites, which consist of silver-multiwalled carbon nanotube-silver, layer-by-layer stacks, can electrically bridge the cracks (>40 μm) that appear in semiconductor substrates and the composite grid lines.Sensing Applied Load and Damage Effects in Composites with Nondestructive Techniques Comparing and correlating piezoelectrically induced guided waves, acoustic emission, thermography, and X-ray imaging to determine the effects of applied load on a composite structure.Technology Impact Forecasting for Multi-Functional Composites Multi-functional composites offer a possible solution to the conflicting design goals of making new aircraft lighter, stronger, faster, and more environmentally sustainable.Molecular Engineering for Mechanically Resilient and Stretchable Electronic Polymers and Composites Establishing the design criteria for elasticity and ductility in conjugated polymers and composites by analysis of the structural determinants of the mechanical…
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Fundamentals of Fatigue Analysis

  • Professional Development
  • C1875
Published 2019-11-26

Fatigue is a structural failure mode that must be recognized and understood in order to develop products that meet life cycle durability requirements. Fatigue strength is an important design requirement in any new vehicle, particularly in the age of lightweighting as engineers struggle to meet stringent weight requirements without adversely impacting durability. This technical concept course provides an introduction to the fatigue failure mode and analysis methods. Attendees will learn about the physics of material fatigue, including damage accumulation which over time may progress to product failure. Attendees will also learn about fatigue analysis methods such as stress-life (SN), strain-life (EN), and crack growth, investigating the assumptions and applicability of each. This course includes example problems which are solved by hand calculation, exploring and reinforcing key concepts. Emphasis is placed on the practical aspects of these concepts and methods so attendees are prepared to put this knowledge into action. This course is popular with both experienced analysis engineers and with engineers transitioning into a durability or analysis role as it provides the needed foundation to develop effective fatigue prediction capabilities.

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High Durable PU Metallic Monocoat System for Tractor Sheet Metal Application

Mahindra & Mahindra, Ltd.-Rahul Lalwani, Sudhir Sawant, Yogesh keskar, Nitin Pagar
Mahindra Research Valley-Vinay Kumar
  • Technical Paper
  • 2019-28-2541
Published 2019-11-21 by SAE International in United States
In sheet metal painting for various applications like tractor and automobiles, most attractive coating is metallic paints. It is widely applied using 3 coat 2 bake or 3 coat 1 bake technology. Both options, results in high energy consumption, higher production through put time and lower productivity in manufacturing process. During various brainstorming and sustainability initiatives, paint application process was identified to reduce burden on environment and save energy. Various other industry benchmarking and field performance requirement studies helped to identify critical quality parameters. There was collaboration with supplier to develop monocoat system without compromising any performance and aesthetic properties. This resulted in achieving better productivity, elimination of two paint layers, substantial reduction in volatile organic content, elimination of one baking cycle and energy saving.Metallic mono-coat formulated using strong polyurethane resins and latest technology pre-coated aluminum pigment for achieving metallic effect in finish. With new resin technology, further reduction in baking temperature and energy is possible.
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Mitigation for Edge Corrosion Protection for Automotive Bodies

Mahindra & Mahindra, Ltd.-Jayanthan Balasubramanian, Rahul Lalwani, Vinay Kumar
  • Technical Paper
  • 2019-28-2561
Published 2019-11-21 by SAE International in United States
A major challenge to automotive industry is to protect the vehicle from corrosion in varying environments with respect to different service conditions. One of the main types of corrosion that affects aesthetic look is edge corrosion on sheet metal. Mostly edge is acting as starting point of corrosion due to unprotected metal exposed to environment. Special attention needs to be given to exposed edges to protect from rust formation.Samples were prepared as per design of experiments with respect to manufacturing process condition, material usage, and design. These samples were tested for corrosion test and painting process compatibility.In this study effect and limitation of burr and optimum solution with respect to corrosion was evaluated and results will be discussed.
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Analysis of Metal Pick-Up Formation Process within Automotive Brake Pad

SAE International Journal of Materials and Manufacturing

Ask Technica Corporation, Japan-Hirokazu Noda
University of Yamanashi, Japan-Takahiro Takei
  • Journal Article
  • 05-13-01-0003
Published 2019-11-19 by SAE International in United States
Metal Pick-Up (MPU) is a problematic phenomenon in automotive disc brakes. MPU generally forms as some metal lumps on the surface of the brake pad. If brake pads have MPU, during braking they would cause grooving of the disc rotor, generating brake noise and deteriorating the performance of the brake. The previous literature has so far reported that the source of the MPU is an Fe component from a disc rotor or brake pads. However, only a few of the generation mechanisms of MPU have been proven. We investigate MPU to completely elucidate the mechanism of MPU generation by using different analyses than the previous literature. First, to find out the source of MPU generation, we focus on the chemical reaction of a certain component with wear debris during braking, and some of the verification experiments are conducted under the conditions of simulated friction interface. Second, to clarify the change in the form of the MPU growth process, the crystal structure of MPU is analyzed in detail by using the world’s largest synchrotron radiation facility…
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Nickel Alloy, Corrosion and Heat-Resistant, Bars, Forgings, and Rings 60Ni - 22Cr - 2.0Mo - 14W - 0.35Al - 0.03La Solution Heat Treated

AMS F Corrosion Heat Resistant Alloys Committee
  • Aerospace Material Specification
  • AMS5891C
  • Current
Published 2019-11-05 by SAE International in United States
This specification covers a corrosion and heat-resistant nickel alloy in the form of bars, forgings, flash welded rings, and stock for forging, flash welded rings, or heading.
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Titanium Alloy Sheet, Strip, and Plate 6Al - 6V - 2Sn Solution Heat Treated and Aged

AMS G Titanium and Refractory Metals Committee
  • Aerospace Material Specification
  • AMS4990D
  • Current
Published 2019-11-05 by SAE International in United States
This specification covers a titanium alloy in the form of sheet, strip, and plate up through 4 inches (101.6 mm).
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Trace Element Control Nickel Alloy Castings

AMS F Corrosion Heat Resistant Alloys Committee
  • Aerospace Material Specification
  • AMS2280D
  • Current
Published 2019-11-05 by SAE International in United States
This specification establishes testing methods and maximum permissible limits for trace elements in nickel alloy castings.
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Steel, Corrosion and Heat-Resistant, Bars, Wire, and Forgings 18Cr - 10.5Ni - 0.60Cb Free-Machining, Solution Heat Treated

AMS F Corrosion Heat Resistant Alloys Committee
  • Aerospace Material Specification
  • AMS5642M
  • Current
Published 2019-11-05 by SAE International in United States
This specification covers two types of free-machining, corrosion and heat-resistant steel in the form of bars, wire, forgings, and forging stock.
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Steel, Corrosion Resistant, Bars and Wire 18Cr - 9Ni (303F) Free Machining, High Yield Strength Solution Heat Treated and Cold Worked

AMS F Corrosion Heat Resistant Alloys Committee
  • Aerospace Material Specification
  • AMS5738E
  • Current
Published 2019-11-05 by SAE International in United States
This specification covers a free-machining, corrosion-resistant steel in the form of cold-worked bars and wire up to 1.750 inches (44.45 mm) inclusive, in nominal diameter or least distance between parallel sides (see 8.5).
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