Browse Topic: Failure analysis

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Improvement of rCF behaviour through the introduction of NF2026-37-0039To be published on 06/09/2026
The use of recycled carbon fibres (rCF) allows for reduction of emissions impacting energy and resource requirements. A major drawback of using rCF composites is the discontinuous nature of the fibres as this limits the performance and applications. The present investigation aimed to overcome some of these limitations by manufacturing hybrid composites by combining rCF and natural fibres (NF). One of the key observations was a significant change in the failure mode of hybrid samples under various loading scenarios, where the composite did not shatter but rather failed in a controlled manner. Initial results also showed an overall improvement impact properties in comparison to plain rCF. Similar performance was observed in other tests. Research was focused on determining the most effective ply sequencing under different types of loading and understanding the effect of the ply sequence on the failure mechanisms. It was determined that depending on the application, the layups does effect
Hnatyk, Dawid, Chrysanthou, Andreas, De Vuyst, Tom, Ismail, Sikiru
Novel material architecture for enhanced high cycle fatigue life in turbofan engine fan blades2026-26-0748To be published on 06/01/2026
High Cycle Fatigue (HCF) is a critical failure mode in turbofan blades, primarily driven by resonance phenomena when the blade’s natural frequency aligns with engine-induced excitations. Traditional approaches to mitigate HCF often involve geometric modifications or damping treatments, which can adversely affect aerodynamic performance or increase component weight. This study explores alternative methodologies to strategically alter the natural frequency of turbofan blades while maintaining aerodynamic efficiency and structural integrity. A novel material architecture is proposed, consisting of a dual-metallic configuration with a high-stiffness core and a lightweight, fatigue-resistant outer shell. This design enables precise tuning of the blade’s dynamic response by leveraging the contrasting mechanical properties of the core and outer materials. The dual-metallic structure shifts the natural frequency away from critical excitation zones, thereby reducing the risk of resonance
S, Ravivarman, Inamdar, Prachi, De, Rohit
Hybrid Physics-Informed Neural Network and PID Control for Fault-Tolerant Autonomous Multi-copters2026-26-0770To be published on 06/01/2026
This paper addresses the critical challenge of fault-tolerant control in autonomous multi-copters, particularly under conditions of one or two rotor failures a scenario that often leads to severe instability and a complete loss of directional control due to unbalanced torque and resultant autorotation. Existing advanced control strategies, including optimal approaches such as LQR, typically require precise system modeling and state estimation, which are difficult to achieve in real-world, dynamic failure scenarios. Alternative methods like fuzzy logic, sliding mode control, and gain-scheduling either lack robust generalization or are impractical for enumerating all possible failure cases. In this work, a hybrid control framework integrating Physics Informed Neural Networks (PINN) with a standard PID controller is proposed for fault-tolerant operation of autonomous multi-copters subject to multiple actuator failures. PINNs incorporate governing physical laws as regularization in their
Charapalle, Samruddhi, Venugopalan, Nandagopalan, Nerkundram Muralidharan, Arun, Sundararaj, Laveen
Assessment of Injection Gate Location effects on Mechanical Performance of Short Fiber Reinforced Plastic Components using Digimat2026-26-0746To be published on 06/01/2026
The mechanical performance of short fiber-reinforced plastic (SFRP) components is highly sensitive to fiber orientation, which is significantly influenced by the injection gate location during the molding process. Traditionally, gate placement decisions are driven by warpage minimization strategies, often overlooking mechanical performance under diverse load cases. This research introduces an automated workflow within Digimat-MS that integrates injection gate optimization into the early design phase, leveraging Integrated Computational Materials Engineering (ICME) principles. The proposed methodology enables engineers to upload either of Marc, Abaqus or Ansys input decks, select a component of interest, assign material cards, and define gate scenarios. A Design of Experiments (DOE) is then executed locally or remotely, allowing Digimat to simulate and evaluate multiple gate configurations. The system aggregates results and identifies optimal gate locations based on the initiation of
Kauthale, Tanmay, Madhavan, Vinay, Soni, Ganesh
Effect of Fluid Flow/Time Duration on Static Voltage Generation for Aerospace Hose Assembly2026-26-0757To be published on 06/01/2026
Static electricity is an electrical imbalance on the surface of a material that can interact with other components made of the same or different materials. Fluid (hydrocarbons) flow within the hose assembly generates static voltage due to the friction caused by fluid flow in pipes, which needs to be appropriately quantified and dissipated. Accumulation of such static charge may lead to sudden discharge, resulting in spark generation. Spark generation around fuel flow might lead to system failure and failure in aircraft engines. Experiments were conducted to analyze the static voltage generated in the hose assembly with a fixed hose assembly length due to fuel flow, with the objective of achieving acceptable voltage levels to avoid ESD (electrostatic discharge) failure. The procedure includes fuel flow rate monitoring and voltage measurement. The testing revealed that the curvature of the hose affects the readings, highlighting the importance of consistent meter alignment. Using a
Waghmare, Shashank
Hybrid Digital Twin for Aero-Engine Bearing Prognostics: A Physics-Informed Machine Learning Approach to RUL Prediction2026-26-0718To be published on 06/01/2026
Unscheduled maintenance due to the failure of critical components, such as aero-engine rolling element bearings, is a leading cause of costly Aircraft-on-Ground (AOG) events; consequently, current time-based maintenance practices are inefficient and prone to risk. This paper develops a resource-efficient Hybrid Digital Twin (HDT) model for an engine bearing, focusing on the dynamic prediction of spall growth due to Rolling Contact Fatigue (RCF), thereby enabling a condition-based maintenance paradigm. The HDT architecture integrates two core models: (1) a physics-informed model that uses established life and fatigue theory to define initial degradation thresholds and constrain the failure envelope, and (2) a data-driven Recurrent Neural Network (RNN) (specifically, an LSTM) for dynamic degradation rate modeling. The methodology utilizes a Monte Carlo simulation coupled with RCF progression equations to generate a large, synthetic run-to-failure dataset under varying operational loads
Mohamed, Abbas
AI Powered Failure Mode and Effect Analysis in Safety Critical Industry2026-01-0106To be published on 04/07/2026
This paper presents the first systematic examination of Large Language Model (LLM) capabilities for automating the development of Failure Mode and Effects Analysis (FMEA) utilizing architectural diagrams as input. Although prior research has examined LLMs for FMEA tasks, our methodology incorporates innovative aspects, such as the direct analysis of architectural diagrams for component extraction, prediction of failure modes, causes, estimation of risk and a human-in-the-loop (Hu-IL) validation framework. We examine the capability of general-purpose LLMs to accurately automate the creation of FMEA by formulating a methodology that extracts components and signals from architectural diagrams, conducts automated component classification, and produces a comprehensive FMEA form sheet encompassing Severity, Occurrence, and Detectability (S/O/D) scoring. Our methodology is grounded in structured prompt engineering theory, utilizing scope bounding techniques to reduce hallucination while
Diwakaruni, Sundara Sasi Koushik, Krishnamurthy, Anunay
Application of Reliability Growth Methods in Conjunction with Design for Reliability Framework to Validate Heavy Truck Design2026-01-0137To be published on 04/07/2026
Why field campaigns in the automotive industry have been going up over the years despite the strong development of technical knowledge, computational design tools and techniques to secure higher reliability standards since early stages of development phases? Uncertainties created by product complexity have been a factor that affects the ability of the manufacturers to prevent design failures before the product launch. Another factor is the shorter product development time, less test time to validate the product means that the new design will not have enough exposure to the real truck application and so some failures may not be able to be detected during the project. To deal effectively with uncertainties this study shows an application of reliability growth techniques in conjunction with DfR- Design for Reliability framework to validate the truck design in the customer application. The Crow - AMSAA method is applied to measure the reliability growth of the complete vehicle in various
Coitinho, Marcos
Analysis of Failures Due to Ant Entry in Automotive Electronic Components and Integration of Learnings in Design2026-01-0193To be published on 04/07/2026
Automotive electronic components are exposed to different environmental conditions, and these conditions may impact the functioning of the components, leading to failures in vehicles globally. These failures often create inconvenience for customers across OEMs. Addressing failures requires measures that incur extra costs. One of the environmental factors is insect entry inside the components. This Quality research paper aims to address the need for revision in design standards due to failures caused by Ant entry. The increase in integration of technology in vehicles has led to an increase in the use of electronic components such as switches, control modules, and controllers. Vehicles are often parked in open areas (under trees, open grounds, basements or construction sites) and are in close vicinity to Ant nests or feeding areas. Ants may be drawn to the warmth and shelter provided by vehicle engine bays and wiring compartments. In some cases, especially in tropical regions, ants have
Marwah, Ramnik, Dasgupta, Saikat, Upadhyay, Siddharth, Joshi, Rohit, Taneja, Bhavnesh, Bose, Sushant, Sharma, Pankaj, Garg, Vipin
Understanding Adversarial Transferability in Vision-Language Models for Autonomous Driving: A Cross-Architecture Analysis2026-01-0170To be published on 04/07/2026
Vision-language models (VLMs) are increasingly used in autonomous driving because they combine visual perception with language-based reasoning, supporting more interpretable decision-making, yet their robustness to physical adversarial attacks, especially whether such attacks transfer across different VLM architectures, is not well understood and poses a practical risk when attackers do not know which model a vehicle uses. We address this gap with a systematic cross-architecture study of adversarial transferability in VLM-based driving, evaluating three representative architectures (Dolphins, OmniDrive, and LeapVAD) using physically realizable patches placed on roadside infrastructure in both crosswalk and highway scenarios. Our transfer-matrix evaluation shows high cross-architecture effectiveness, with transfer rates of 73–91% (mean TR = 0.815 for crosswalk and 0.833 for highway) and sustained frame-level manipulation over 64.7–79.4% of the critical decision window even when patches
Fernandez, David, MohajerAnsari, Pedram, Salarpour, Amir, Pese, Mert D.
Advancing Safe Battery Design through Experimental Cell Characterization of Thermal, Electrical and Mechanical Properties2026-01-0408To be published on 04/07/2026
Lithium-ion batteries are critical to Electric Vehicles (EV) and grid-scale energy storage. Safe design of battery systems relies on accurate simulation of thermal runaway under electrical, thermal, and mechanical abuse. A predictive battery simulation requires characterization of electrical, thermal, and mechanical properties at the full cell and cell-component levels. In this study, a commercial cell from an EV was disassembled, and tested to support both homogenized and detailed computational models. At the cell level, electrical properties were characterized using Hybrid Pulse Power Characterization (HPPC) testing to assess the cell’s power capability. Full cell compression tests were conducted to characterize mechanical behavior under deformation and used to develop a multi-physics homogenized cell model. On the other hand, detailed cell modeling that includes different component layers could help users understand localized cell integrity under mechanical deformation. At the
Challa, Vidyu, Rostami-Angas, Masoud, kong, Kevin, Wang, Leyu, Reichert, Rudolf, Kan, Cing-Dao
CrashML Analyzer: A Data-Driven Approach for Investigation and Fault Assignment in Autonomous Driving Collisions2026-01-0160To be published on 04/07/2026
This study investigates factors contributing to autonomous vehicle (AV) accidents and proposes an automated fault determination framework. A total of 563 accident reports from the State of California Department of Motor Vehicles spanning from 2019 to 2024 were analyzed by converting unstructured standardized reports into structured data using custom extraction tools. Analysis of these reports reveals that AVs were not at fault in 69.4% of cases and were fully at fault for 22.6% of cases. The proposed method uses these reports to provide an early indicator of fault likelihood and potentially replaces tedious manual review. Machine Learning (ML) and Natural Language Processing techniques were used to replicate the reported faults, achieving 96% average accuracy across three models: Gradient Boosting, Linear Regression, and Random Forest. Through feature engineering techniques in semantic feature extraction from narrative accident descriptions, quantifiable variables were obtained and
Rwejuna, Florida Perfect, Majid, Nishatul, Goutham, Mithun, Loukili, Alae
CFD-Based Investigation of Fuel Tank Sloshing: Crash Safety and Noise Concerns2026-01-0490To be published on 04/07/2026
A computational study using the Volume of Fluid (VOF) method in SimericsMP+ was conducted to investigate fuel sloshing in automotive fuel tanks under both crash and sudden stop conditions. The SEALs method was employed to rapidly generate the fuel tank mesh, enabling efficient simulation setup. At the outset, a benchmark sloshing case was simulated and compared against experimental data, showing excellent agreement to validate the simulation method. This simulation method was then applied to the fuel tank sloshing scenarios mimicking crash and sudden stop conditions. The study initially focused on a crash scenario in which fuel waves impact valves, pumps, and other internal structures. Capturing these localized impact forces is critical for evaluating the risk of component failure and potential leakage. A baffle-equipped tank was simulated and compared with sensor data. Results show that the computed shock forces on valves and baffles closely matched the measurements, demonstrating the
Jia, Kun, Rahman, Ashique, Pandey, Ashutosh
Optimizing Joint Efficiency in Stainless Steel-Aluminum Alloy FSW Joints through Advanced Parameter Control2026-01-0228To be published on 04/07/2026
The present study investigates optimization of ultimate tensile strength (UTS) in FSW of AA2024-T3 and SS304 in a butt joint configuration. An L18 mixed-level orthogonal array was used to design 18 experiments, varying tool rotational speed (450, 560, and 710 rpm), traverse speed (20, 25, and 40 mm/min), and pin offset (1 and 1.5 mm toward the Al side). The tool rotational speed had the greatest influence on UTS, contributing nearly one-third of the total variance, followed by pin offset and traverse speed. The optimal combination, 450 rpm, 20 mm/min, 1.5 mm offset, yielded a UTS of 344.7 MPa and a joint efficiency of 78.3%. At this setting, peak temperatures reached ~356 °C, ensuring sufficient plasticization and uniform mixing of the Al–SS interface, producing a refined stir zone with an average grain size of 4.2 μm. Fracture analysis revealed ductile failure at the optimal parameters, whereas suboptimal conditions resulted in brittle or mixed fractures due to either insufficient or
Mir, Fayaz Ahmad, Khan, Noor Zaman, Pali, Harveer Singh
EV Propulsion Drive Converter SiC Power Device Over-Temperature Protection under Low Motor Speed Operation2026-01-0436To be published on 04/07/2026
Monitoring power device temperature in an electric vehicle propulsion drive converter is extremely important to achieve full power delivery within the maximum power capability envelope. Usually, on-die temperature sensors are installed on Si-IGBT power devices in electric vehicle propulsion drive converters to enable monitoring device temperature and achieve over-temperature protection. Currently, SiC MOSFET is a promising power device in power converters of electric drives because of its lower loss, higher switching speed, higher voltage capability, and higher junction temperature limit in comparison with the widely used Si-IGBT. However, SiC MOSFET is a more expensive device, installation of an on-die temperature sensor on SiC MOSFET will significantly increase its cost and complexity. So presently, there is no junction temperature sensor installed in SiC MOSFET due to which there is great difficulty protecting SiC MOSFET from over temperature. When a junction temperature estimation
Thongam, Jogendra Singh, Ge, Baoming, Bradford, Steven, Kulkarni, Milind
A Dataset for Visual Classification of Bulging Pouch Battery Cells2026-01-0393To be published on 04/07/2026
The rapid advancement of lithium-ion battery technologies, particularly pouch cells, has driven significant growth in electric vehicles, mobile devices, and renewable energy storage. However, pouch cells are especially susceptible to mechanical deformation and failure, including bulging caused by internal gas formation—a common indicator of cell aging or imminent failure. In this study, we developed a visual dataset of bulging pouch battery cells to support real-time diagnostics and safety monitoring in industrial and laboratory environments. The dataset includes 200 high-resolution images (100 bulged, 100 normal) curated through a web-crawling and filtering pipeline. The dataset is benchmarked across several traditional machine learning models to evaluate performance and feasibility for edge AI deployment. The best model achieved strong classification accuracy while maintaining a small computational footprint suitable for embedded applications.
Alkawasmie, Mohammad, Farooqui, Saad, Algalham, Dheya, Rahman, Mahfilur, Challa, Karthikeya, Maxim, Bruce, Shen, Jie
Compact, Low-Cost Ultra-Low NOx Solution for 2027 US EPA, Euro VII, China VII and Off-Road2026-01-0363To be published on 04/07/2026
Achieving ultra-low NOx emissions remains a major challenge in diesel emission control industry worldwide, especially as increasingly stringent regulations are introduced globally. Selective Catalytic Reduction (SCR), the leading NOx reduction technology in diesel systems, performs best when “sufficient” heat and ammonia are made available to it. At the same time, any proposed solution must be both low-cost and functionally robust in an industry seeking near 100% NOx removal at the lowest feasible cost. This work presents a low-cost architecture, utilizing a small, highly compact, single heater-mixer unit along with a light-off (close-coupled) SCR for meeting most stringent NOx emission regulations worldwide. It also hinders deposit formation lowering warranty costs and mitigating failure modes. Engine studies using a fully-aged aftertreatment system demonstrate that the proposed solution enables compliance with newer heavy-duty regulations including 2027 US, Euro-VII, China-VII, and
Masoudi, Mansour, Poliakov, Nick
A Study on Fail-Safe and Limp-Home Strategies for Electric Drive Failures in P1-P2 (P)HEVs2026-01-0427To be published on 04/07/2026
Hyundai Motor Company’s TMED-II hybrid system adopts a P1–P2 parallel motor layout, which improves power distribution flexibility but increases reliance on electric drive components. Failures in motors, inverters, or other power electronics can critically affect drivability and safety, making robust Fail-Safe strategies essential. This study proposes a three-stage, sequential Limp-Home strategy for P1–P2 HEVs under P2 motor system failure. Unlike conventional methods that open the main relay and rely solely on the engine, the proposed approach keeps the high-voltage (HV) system active whenever possible to maintain performance, safety, and comfort. Stage 1 – P1 motor-based State of Charge (SOC) control: Keeps the main relay closed and uses the P1 motor to maintain SOC within set limits. Overcharge is mitigated by operating the motor in discharge mode, and overdischarge is mitigated through regenerative operation. Engine torque is adjusted to match motor torque demand, preserving launch
Rho, Jeongwon, Park, Sangcheol, Oh, Sung Hwan
From Algorithm to Engineering Judgment: Navigating Topology Optimization’s Limits in Crash Applications2026-01-0189To be published on 04/07/2026
The non-linear nature of crash scenarios has led to many designs being developed through extensive trial and error based on the intuitions of the design engineer. As such, effectively utilizing topology optimization for crash applications offers opportunities to provide major improvements in cost, weight, and passenger safety. Topology optimization is known for creating stiff, lightweight structures, however its application to crash scenarios must be handled carefully. Compliance minimization, the most common optimization objective, can yield misleading designs that prioritize undesirable qualities when developing structures for crash applications. In this paper, the design process of a passenger seat assembly subject to sequentially applied enforced displacement, and crash deceleration loads is discussed. Due to the conflicting nature of compliance minimization and enforced displacement, the design was split into two types of regions; sacrificial, which are regions manually designed
Orr, Mathew, Shi, Yifan, Lee, Jake, Gray, Savannah, Park, Taeil, Wotten, Erik, LeFrancois, Richard, Huang, Yuhao, Patel, Anuj, Kim, Hansu, Burns, Nicholas, Jalayer, Shayan, Grant, Robert, Kok, Leo, Hansen, Eric, Kim, Il Yong
The ML FMEA in Action: Lessons from Applications of Machine Learning Safety2026-01-0079To be published on 04/07/2026
Introducing machine learning (ML) into safety-critical systems presents a fundamental challenge, as traditional safety analysis techniques often struggle to capture the dynamic, data-driven, and non-deterministic behavior of learning-enabled components. To address this gap, the Machine Learning Failure Mode and Effects Analysis (ML FMEA) methodology was developed as an open-source framework tailored to ML-specific risks. This paper reports on the maturation of ML FMEA from an initial conceptual framework to a proven, practice-driven methodology. We make four primary contributions. First, we extend the ML FMEA pipeline with two new stages: a “Step Zero” for problem definition and system-level hazard analysis, and a “Step 5” for constructing ground truth or reward signals. Autonomous vehicle and humanoid robot applications are presented to illustrate the practical application and safety benefits of these additions. Second, we introduce tailored Severity, Occurrence, and Detection
Schmitt, Paul, Shinde, Chaitanya, Diemert, Simon, Pennar, Krzysztof, Seifert, Bodo, Poh, Justin, Lopez, Jerry, Mannan, Fahim, Mohammed, Majed, Chalana, Akshay, Wadhvana, Neil, Wagner, Michael
Advanced Wheel Attachment Loosening Identification through Algorithmic Gear Error Analysis and Probabilistic Assessment2026-01-0590To be published on 04/07/2026
At present, tire failures directly affect road safety, and the number of incidents caused by them is gradually increasing. Examining wheel attachment loosening on time is vital for vehicle safety. Tire-related incidents not only put people in peril but also have a detrimental effect on the economy. Therefore, the goal of this research is to develop a new and effective method for identifying wheel attachment loosening. A novel gear error reduction approach, distinct from traditional methods, combines advanced computing and probabilistic analysis. This paper involves three key components: extracting looseness eigenvalues, calculating ring gear errors, and computing the tire loosen probabilities. Gear errors derived from the Kalman filter and adjusted for speed, eigenvalues were calculated, and a tire loosening probability analysis was performed. Real-car trials across speeds and roads confirm its accuracy and reliability. This technology can improve automotive safety and maintenance
Liu, Jianjian, Zhang, Zhijie, Wang, Zhenfeng, Ma, Guangtao, Shi, Meijuan, Liu, Jing, Zhao, Binggen, Lu, Yukun
Strain-Based Fracture Assessment of Tailor Welded Blanks under Complex Loading Conditions2026-01-0231To be published on 04/07/2026
Tailor Welded Blanks are critical for automotive lightweighting yet prone to premature failure due to differential thickness and strength across the weld. This study utilized digital image correlation (DIC) to analyze the maximum in-plane principal Hencky strain (E₁max) and axial strain (εₐₓₐₗ) of TWBs under complex loading conditions, including biaxial and plane-strain states. Twelve distinct material stack-ups were tested to evaluate the impact of material difference on formability. Results indicated that differential properties significantly altered strain distribution, often forcing localization onto the thinner or softer sheet. While UHSS welds provided high load capacity with limited ductility, combinations using HSLA or IF substrates were susceptible to early localization and unstable fracture. Comparative heatmaps illustrate strain evolution across all samples, providing spatial insights beyond conventional force–displacement analysis. Metallurgical characterization confirmed a
Aminzadeh, Ahmad, Sheng, ZiQiang, Huang, Lu, McCarty, Eric, Biro, Elliot
Enhanced CAE Methodology to Predict Bolt Shear Failure Using Multi-Layer Approach2026-01-0489To be published on 04/07/2026
Automotive seat system is one of the most complex systems in vehicle for its technical and functional requirements. Seat is designed to meet all regulatory requirements subjecting it to multiple tests with loading patterns which caters to the occupant safety. Varied loading and load path for different test requirements cause seat bolts to experience tensile, compressive, bending moments and shear loading. Shearing along bolt length is one of the common failure modes observed during design validation by physical tests. In the world of CAE, there is an industry approach to find the bolt failures at nut and head for all kind of loads. But shear failures along varied bolt lengths are not accurately predictable as multiple sheet metal parts will transfer loads unevenly onto bolt length and it becomes challenge to find which component is leading to shear failure. Hence by adding multiple rupture layers across the bolt length shear and its location could be predicted. Further, to resolve the
RJ, Jethendra, Chiu, Li-Ban
A Novel Spot Joint Finite Element for Rapid Stress Analysis of Fasteners in Automotive Structures2026-01-0182To be published on 04/07/2026
Due to the spot weld and mechanical fastener share the similar characteristics to join sheets together with differences in deformation behavior around joint region, a novel spot joint element (user-defined element) consists of regular Mindlin shell elements and equations for different kinematic constraints is proposed to simplify the spot joint representation in lightweight automotive structures. The novel spot joint element can not only provide accurate deformation behavior around joint region but also output mesh-insensitive structural stresses at virtual nodes with the use of traction-based structural stress method for fatigue failure analysis. In this investigation, the structural stress distributions around joint circumference in the lap-shear specimens with spot weld or fastener are first calculated to validate the accuracy of the novel spot joint element. Then, the structural stresses along different cross-sections emanating from joint are also calculated for the specimens with
Wu, Shengjia, Zhang, Lunyu, Dong, Pingsha
Development and Validation of a Self-Propelled Trailer: A Standards-Based Approach to Enhancing Compact Vehicle Towing2026-01-0055To be published on 04/07/2026
This paper presents a structured test plan for the development and validation of a Self-Propelled Trailer (SPT), an emerging concept designed to enhance the towing capacity of compact, fuel-efficient vehicles. Unlike conventional trailers, the proposed system integrates electric propulsion and autonomous sensing to actively assist the towing vehicle, reducing engine load and improving both safety and fuel economy. The methodology employs a Design Failure Mode and Effects Analysis (DFMEA) to systematically identify potential risks, while incorporating Society of Automotive Engineers (SAE) standards to guide environmental durability testing (dust, water ingress, gravel impact) and dynamic performance evaluations (gradeability, braking, and stability). A comprehensive set of test procedures is outlined to validate system reliability, robustness, and compliance with established towing requirements. The study demonstrates how powered trailer technology can extend the practical use of
Reilly, Carter, Peters, Diane, Zadeh, Mehrdad
High Strain-Rate Behaviors of Fiber Reinforced Composites in Principal and Off-Axis Directions2026-01-0175To be published on 04/07/2026
Materials can exhibit significantly different mechanical behaviors compared to quasi-static conditions at high strain rates (> 100 s-1). High strain rate tests using setups such as SHPB (Split-Hopkinson Pressure Bar) can provide, in a practicable manner, the stress-strain relations for a material at high strain rates. Such properties are vitally needed for activities such as simulation-driven impact safety design of composite structures deployed in the form of automotive body parts and assembly, and other sub-systems. Although the behaviors of isotropic and ductile materials such as various metallic alloys appear to have been extensively studied and reported in literature, dependence of mechanical properties of fiber-reinforced composites especially in different off-axis directions are extremely difficult to come across. To fill up this void, a detailed experimental study has been carried out on high strain rate mechanical characterization of orthotropic glass, carbon and a natural
Bawa, Prashant, Deb, Anindya, Zhu, Feng
Analysis of Failure Causes and Optimisation of Automotive Cycloidal Rotor Pumps2026-01-0184To be published on 04/07/2026
Cycloidal rotor pumps are widely employed in automotive and aerospace industries due to their compact structure, high volumetric efficiency, and minimal flow pulsation. With the advancement of new energy vehicles, rotor pumps are increasingly required to operate reliably under more demanding conditions, including higher rotational speeds, elevated pressures, and more severe operating environments. These requirements place greater emphasis on pump durability and structural integrity. This study investigates a fracture failure of the internal rotor observed during bench testing of a cycloidal rotor pump. Metallographic and physicochemical analyses were conducted on the failed rotor. The results indicated that the fracture was not attributable to material defects. Instead, the failure originated from improperly designed slot locations within the rotor, which created a structural weak point at the slot opening. Additionally, sharp corners introduced during machining of the slots resulted
Li, Meng, Xie, JIa, Qin, Gongyu, Yang, Hanming, Wang, Liangmo
Investigation of Failure Mechanisms in Lithium Metal Solid-State Batteries Based on In Situ Electrochemical Impedance Spectroscopy2026-01-70362/27/2026
With the growing global demand for sustainable energy and high-performance mobile devices, lithium metal solid-state batteries (LMBs) have emerged as a research hotspot in the field of energy storage due to their exceptional high energy density and significant safety advantages. However, the growth of lithium dendrites and their penetration through the solid electrolyte remain key issues leading to battery short-circuiting and failure. To date, there has been a lack of effective in situ research methods to reveal the failure mechanisms, which has severely restricted the commercialization of LMBs. This study innovatively employs in situ electrochemical impedance spectroscopy (EIS) to investigate lithium plating behavior in symmetric cells during critical current density (CCD) tests under room temperature and elevated temperature conditions. By analyzing characteristic signals at 1 MHz, this study presents the in situ impedance changes at the grain boundaries and interfaces of the
Liu, Zexuan, Wu, Senming, Chen, Ying, Luan, Weiling, Chen, Haofeng
Failure Cause Analysis of Valve-Regulated Lead-Acid Battery on Fire in Communication Equipment Room2026-01-70222/27/2026
This paper carried out the fire failure analysis of valve-regulated lead-acid battery in communication equipment room. Through disassembly and observation of the battery and iron frame of battery cabinet in the area of fire origin, we obtained the key residual traces and used the physical and chemical analysis methods such as macroscopic/microscopic morphology, EDS, X-ray and metallographic, it was finally judged that the leakage of the battery electrolyte lead to the connection of the battery electrode plate and the iron frame and subsequently the electric heating fault caused the fire accident. Furthermore, we put forward some suggestions according to the existing problems, which may contribute to the prevention of similar failures.
Guo, Yuhang
Failure Analysis of Li-Cu Reference Electrode in NCM811||Gr Pouch Battery2026-01-70122/27/2026
Reliable monitoring of the internal state of lithium-ion batteries (LIBs) is crucial for mitigating potential safety hazards. The incorporation of a reference electrode (RE) within the battery constitutes a vital approach for achieving single-electrode monitoring and understanding changes in electrode state during cycling. Among these, the lithium-copper reference electrode (Li-Cu RE) is particularly cost-effective and straightforward to prepare, being fabricated by depositing lithium onto a copper wire. However, Li-Cu RE exhibits a relatively short effective lifespan during long-term cycling, thereby limiting its practical application. In this work, based on a self-fabricated three-electrode single-layer pouch cell, the microstructural changes before and after failure of the Li-Cu RE were characterized and analyzed, revealing its failure evolution process. Post-failure microstructures observations exhibit marked porosity in the electrode, attributed to substantial depletion of surface
Hu, Jiaxing, Luan, Weiling, Chen, Haofeng, Chen, Ying
Real-Time Fault Diagnosis and Reliability Analysis in Lithium-Ion BESS via Bayesian Fault Propagation Networks2026-01-70232/27/2026
The rapid integration of intermittent renewable energy sources (RES) poses significant operational challenges for modern power systems. Lithium-ion battery (LIB)–based battery energy storage systems (BESS) have become vital for grid stability and energy management. However, large-scale deployment of BESS has led to increasing incidents such as fires and explosions, raising serious concerns regarding their safety and reliability. To overcome the limitations of traditional reliability assessment methods—such as reliability block diagrams (RBD), fault tree analysis (FTA), and Markov models—this study proposes an integrated fault detection and reliability analysis framework that combines FTA, failure mode and effects analysis (FMEA), and a Bayesian Fault Propagation Network (BFPN). The framework systematically models fault propagation across component, subsystem, and system levels, dynamically updating the prior probabilities of basic failure events using a Gaussian Mixture Model (GMM) and
Yang, Zhan, Chen, Xiaobo, Zheng, Ruixiang, Li, Mian
Business Reliability Growth for Automotive Engineering, Volume 4R-5522/17/2026
In a world where every business process is under pressure to perform faster, safer, and more reliably, this book delivers a powerful roadmap for sustained operational excellence. Centered on the proven methodology of Design of Experiments (DOE), it shows how organizations can move beyond reactive problem-solving to systematic reliability growth. From well-defined standard operating practices to management-level decision-making, the book connects strategy, data, and execution to create repeatable, measurable results across the enterprise. Readers are guided through practical, real-world applications of DOE, from selecting the right factors and levels to executing robust experiments, analyzing outcomes, validating solutions, and continuously monitoring performance. Each chapter translates complex statistical and engineering concepts into actionable business value, helping teams improve quality, reduce waste, and increase return on investment. Key capabilities explored in this book
Chiang, Young J.
Dual use Electric Vehicle Infrastructure for Enhancing Grid Resilience and Urban Sustainability2026-28-01142/12/2026
The growing global adoption of electric vehicles (EVs) has resulted in a spike in the number of EV charging stations. As EVs have become more and more popular worldwide, a large number of EV charging stations are opening up to accommodate their demands. During grid failures, an EV charging station can also serve as a flexible load connected to the grid to balance out voltage fluctuations. An EV charging station when powered using a separate source, such as solar or wind, can function as a powerhouse, bringing electricity to the grid when it's needed. Therefore, instead of installing more equipment to sustain voltage, the current EV charging station can be efficiently used to meet the grid's needs during failures. These stations have the potential to be dynamic, grid-connected assets for sustainable cities and communities in addition to their core function of vehicle charging (SDG 11). Because of their dual purpose, they can serve as adaptable loads that reduce voltage variations during
R, Uthra, Rangarajan, Ravi, D, Suchitra, D, Anitha
Evolution of a Novel Hybrid Stab-Link for a Born Electric Sports Utility Vehicle2026-28-00012/12/2026
The present study details the design evolution and failure analysis of a novel hybrid stabilizer bar link (stab link) developed for the front suspension of a born electric sports utility vehicle (SUV) platform characterized by higher gross vehicle weight (GVW), increased wheel travel, and constrained packaging space. To address these challenges, a unique hybrid stab link was designed featuring dual plastic housings at both the metal ball joint ends, connected by a steel tube, and achieving a 30% weight reduction while offering enhanced articulation angles for extremely lower turning circle diameter (TCD) of the vehicle, compared to the conventional stab link. The unique hybrid stab failed under complex loading conditions during accelerated durability testing (ADT), prompting a comprehensive investigation. The failure analysis included road load data acquisition across various stab bar diameter configurations evolved during suspension tuning, different stabilizer link designs evolved
Selvendiran, P, J, Ramkumar, Nayak, Bhargav, M, Sudhan, Patnala, Avinash
Common Mode Voltage Reduction in Quasi-Z Source Inverter for Electric Vehicle Applications Using MBPWM Technique2026-28-01022/12/2026
Unlike traditional voltage source or current source inverters, ZSI/qZSI can boost and invert DC power in a single stage, making them attractive for applications like EVs where battery voltage may vary. Common mode Voltage (CMV) is the voltage between the neutral point of the motor and ground. High CMV in motor drive systems can cause: Higher leakage currents, Electromagnetic interference (EMI), Insulation stress, bearing currents, leading to premature motor failure. Reducing CMV is essential for reliable and safe EV operation. Pulse-width modulation (PWM) is used to control the QZSI output voltage. The QZSI offers several advantages over traditional inverters, including improved efficiency, reduced cost, and increased reliability. The proposed system is designed to reduce the CMV through a combination of passive LC filtering and shoot-through (ST) modulation techniques. The LC filter is designed to attenuate high-frequency components of the CMV while the ST modulation is used to
N, Kalaiarasi, R, Rajarajeswari, D, Anitha
Modelling and Analysis of Complex Shaped Cracks2026-28-00482/12/2026
This study provides an extensive analysis through finite element analysis (FEA) on the effects of fatigue crack growth in three different materials: Structural steel, Titanium alloy (Ti Grade 2), and printed circuit board (PCB) laminates based on epoxy/aramid. A simulation of the materials was created using ANSYS Workbench with static and cyclic loading to examine how the materials were expected to fail. The method was based on LEFM and made use of the Maximum Circumferential Stress Criterion to predict where cracks would happen and how they would progress. Normalizing SIFs while a crack was under mixed loading conditions was achieved using the EDI method [84]. We used Paris Law to model fatigue crack growth using constants (C and m) for the materials from previous studies and/or tests. For example, in the case of titanium Grade 2, we found Paris Law constants with C values from 1.8 × 10-10 to 7.9 × 10-12 m/cycle and m values from 2.4 to 4.3, which illustrate differing effects of their
T, Lokesh, Bhaskara Rao, Lokavarapu
Methodology for Shower Water Management in Electric Car Applications2026-28-00682/12/2026
All automotive vehicles with enclosed compartments must pass the shower test standard - IS 11865 (2006). One of the most severe and critical areas of water leakage is “water entry into HVAC (heating, ventilation, and air conditioning) opening”. Excess water flow at high-pressure conditions and seepage during long-time low-pressure conditions could potentially have a significant impact on water entry inside the HVAC suction cutout given on BIW (body in white) and subsequently into the cabin. The present study clearly indicates that for making leak proof HVAC opening (suction interface), it is crucial for the structure of BIW plenum, plenum applique, and its sealing components to be robust enough to effectively collect and divert the water during rainy seasons.
Gunasekaran, Mohanraj, Namani, Prasad, Ramaraj, Rajasekar, Junankar, Ashish, Raju, Kumar
Genetic Algorithm Based Optimization of Chaboche Kinematic Hardening Parameters along with the Validation of FE Model through Characterized Crack Initiation2026-28-00862/12/2026
In the context of electro-mobility for commercial vehicles, the failure analysis of a connector panel in a DCDC converter is crucial, particularly regarding crack initiation at the interface of busbar and plastic component. This analysis requires a thorough understanding of thermo-mechanical behavior under thermal cyclic loads, necessitating kinematic hardening material modeling to account for the Bauschinger effect. As low cycle fatigue (LCF) test data is not available for glass fiber reinforced polyamide based thermoplastic composite (PA66GF), we have adopted a novel approach of determining non-linear Chaboche Non-Linear Kinematic Hardening (NLK) model parameters from monotonic uniaxial temperature dependent tensile test data of PA66GF. In this proposed work a detailed discussion has been presented on manual calibration and Genetic Algorithm (GA) based optimization of Chaboche parameters. Due to lack of fiber orientation dependent test data for PA66GF, here von Mises yield criteria
Basu, Parichay, Srinivasappa, Naveen
Rewriting the engineer's playbook: What OEMs must do to spin the AI flywheel26AUTP02_042/1/2026
The automotive industry's future hinges on a new AI-native engineering workflow that accelerates iteration, strengthens system thinking, and preserves human judgment. Automotive development cycles are compressing at a pace the industry has never seen. The shift to all-electric fleets of software-defined vehicles is moving faster than traditional processes can absorb. In parallel, regulatory pressure and customer expectations keep rising, demanding greater performance, higher safety, better energy efficiency, and sharper competitiveness. In this environment, OEMs R&D competitiveness depends on three factors: How quickly teams can explore and iterate on design choices while delivering differentiated value, product performance, and cost efficiency. How early system-level interactions can be detected, before they turn into delivery friction or costly late-stage failures. How effectively a company can encode and scale its internal engineering know-how into lean development processes.
Allard, Théophile
A proactive approach to hydraulic health in Class 8 trucks26TOFHP02_072/1/2026
For any fleet or logistics manager, the specter of a downed Class 8 truck is a constant concern. The costs aren't just in parts and labor; they're in lost productivity, missed deadlines and potential damage to your reputation. While many factors can sideline a heavy-duty vehicle, one of the most persistent and costly culprits is hydraulic system failure. These failures often trace back to a single, preventable issue: contamination.
Lapierre, Luc
The Critical Impact Of SAE Aerospace Standards: Certified AS1895/7 and /23 Metal Seals26AERP02_092/1/2026
How engineers can ensure safety, reliability and quality in aerospace systems. Courbevoie, Île-de-France In an industry where failure is not an option and precision is paramount, aerospace manufacturers and suppliers are constantly seeking components and system solutions that deliver trusted reliability, performance, and compliance. Industry standards are a key part of achieving these high expectations, bringing together global leaders in the mobility industries to create defined, repeatable methods and consistent processes. One of these aerospace standards is AS1895 developed by SAE International - a critical standard due to the need for durable components that can withstand extreme conditions and offer high performance: high-temperature resistance, pressure sealing, and long service life with a cost-effective installation method. Leading aerospace companies such as Eaton and Honeywell have been manufacturing components that meet this standard for a long period of time.
Challenges in Compliance Testing of Off-Board Electric Vehicle Chargers: Analysis of Typical Failures and Remedial Measures2026-26-05821/16/2026
As India accelerates the adoption of electric vehicles (EVs) the development of a scalable, reliable and efficient charging infrastructure becomes critical to ensuring the success of EV adoption. During type testing, the off board AC/DC EV chargers undergo a comprehensive assessment to ensure they meet safety and performance standards required by regulations. The tests examine crucial factors like electrical safety, EMC (electromagnetic compatibility), interoperability, environmental endurance and mechanical strength. This paper provides information of the India mandatory compliance requirements and highlights typical failure modes observed during the validation process of off-board chargers. Emphasis is placed on challenges associated with electrical safety, EMC performance and interoperability. The objective is to support charger manufacturers to identify potential issues during design and development.
Murumkar, Aditya, Mulay, Abhijit B
Investigating Thermal Fatigue Cracks in Exhaust Manifolds of Longitudinally Mounted 1.2L 4-Cylinder Engines2026-26-04881/16/2026
This study addresses the challenge of ensuring the durability of closed couple exhaust manifolds in the compact engine bays of modern vehicles, focusing on a longitudinally mounted 1.2L 4-cylinder engine. The original sheet metal Exhaust manifold design failed the thermal fatigue bench durability test, requiring a complete redesign to improve strength without changing materials. Initial simulation predictions significantly deviated from physical test results, with repeated cracks observed during accelerated thermal fatigue bench testing, despite simulations predicting a higher number of cycles before failure. This difference highlighted the need for a deeper understanding of the manifold's failure modes, primarily thermal fatigue, and mechanical vibration during engine transients. The design of experiment (DOE) approach was used to find the effect of different parameters e.g., gas temperature, surface temperature, air flow, thermal gradient, on the durability result & also to
Krishnan, K.S.Gopala, Mishra, Ashutosh, Yadav, Sanjay Kumar, Kumar, Deepak, Tripathi, Manas, Kumar, Prabhakar
SEooC- Based Design Framework Integrated EV Power Conversion Systems under ISO-26262 Compliance2026-26-01921/16/2026
The work completed on “System level concepts to test and design integrated EV system involving power conversion to satisfy ISO26262 functional safety requirement” is included in the paper. Integrating power conversion and traction inverter subsystems in EVs is currently popular since it increases dependability and improves efficiency and cost-effectiveness. Maintaining safety standards is at danger due to the growing safety requirements, which also raise manufacturing costs and time. The three primary components of integrated EV systems are the PDU, DC-DC converter, and onboard charger. Every part and piece of software is always changing and needs to be tested and validated in an economical way. Since the failure of any one of these components could lead to a disaster, the article outlines the economical approaches and testing techniques to verify and guarantee that the system meets the functional safety criterion.
Uthaman, Sreekumar, Mulay, Abhijit B, Gadekar, Pundlik
A Systematic Debugging Methodology for Identifying Electric Vehicle Level EMC Issues2026-26-05251/16/2026
Electric vehicles present unique challenges in electromagnetic compatibility testing due to compact packaging, high-frequency switching systems. This paper presents a systematic debugging methodology for identifying radiated emission and radiated immunity issues in these EV platforms. A comprehensive approach is outlined, covering radiated emission measurement; Bulk Current Injection based immunity simulation, and near-field probing techniques. For RI evaluation, BCI testing in the 20 to 400 MHz range is used to simulate radiated threats on the vehicle's power and signal harnesses and handy transmitter near field injections for higher frequency simulation. For RE diagnosis, conducted emission measurements on vehicle harnesses are performed using current probes to capture high-frequency currents. Additionally, near-field electric probes are used at the component to identify dominant noise sources such as DC-DC converters, Motor control unit, and improperly grounded shielding. Case
M, Gokul, Patel, Jinay, Mulay, Abhijit B
An Investigation into the Structural Impacts of Off-Road Maneuvers on Rear Axle Upper Link Mounting Bracket2026-26-04901/16/2026
Multi-link rigid axle suspension is widely used as a rear suspension system for body-on-frame SUVs. The upper link in a multi link rear suspension plays a critical role in managing the vertical and longitudinal positioning of the axle, while the lower link ensures stability by regulating the axle's movement in the horizontal plane. This coordinated functionality of upper and lower link allows for controlled axle dynamics during compression and rebound, significantly enhancing ride comfort and improving vehicle handling characteristics. This study examines the failure of an upper link mounting bracket on the rear axle of an SUV during off-road events, despite no failures observed in other durability tests. Root cause analysis is conducted on failed samples to determine the specific reasons for failure only in off-road conditions. Additionally, the investigation focuses on understanding the dynamic loads experienced by the upper link during vehicle operation across various durability
J, Akhil, Senthil Raja, T, Ghumare, Dheeraj, Chilakala, Raghavendra, Kundan, Lal, Mohapatra, Durga Prasad
Robust Validation of Rotary Switch with TFT Display in Hardware in Loop Simulation2026-26-05401/16/2026
Modern automotive systems are increasingly integrating advanced human-machine interfaces, including TFT displays, to enhance driver experience and functionality. Ensuring the reliability of these systems under diverse operating conditions is critical, especially given their role in vehicle control. This paper presents a Hardware-in-the-Loop (HIL) testing methodology for validation of rotary switch with TFT display. The HIL setup simulates real-world vehicle conditions, including CAN communication, power fluctuations and user interactions, enabling early detection of potential failure modes such as display flickering or communication loss. The results demonstrate improved robustness and reliability of the gear selection switch, supporting its deployment across multiple vehicle platforms.
Bhuyan, Anurag, Jahagirdar, Shweta, Khandekar, Dhiraj
A Machine Learning Approach to Early-Stage Failure Prediction in Traction Motor Manufacturing2026-26-02811/16/2026
Traction motors technology has, driving the EV industry forward with more efficient, lightweight, and durable solutions. However, despite these advancements, noise testing at the end of the production line remains a critical stage for identifying manufacturing defects in traction motors. Hence early fault detection in traction motors is crucial to ensure safety and reliability of EV. This research contributes a solution that predicts early-fault detection, supporting improved reliability, reduced material cost and minimizing process time in the series production line. To identify the root cause of this problem, historical quality data has been acquired from manufacturing plants to enable efficient analysis. Feature selection was then carried out using embedded and wrapper methods to identify the most important features. These selected features were subsequently used as input for ML models. The best accuracy was achieved using SVC model for early-stage motor failure prediction.
Gaikwad, Pooja, Nangare, Kapilraj, Suryawanshi, Chaitanya
Comparative Study of ADC12, A356, and AlSi10Mg Alloys in Sand Casting of EV Battery Housing2026-26-02961/16/2026
This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines
Subramani, Rajesh, Singh, Gajendra, Doddamani, Mrityunjay
Bearing Creep Prevention in EV Transmission2026-26-05981/16/2026
As the trend shifts from Internal Combustion Engine (ICE) vehicles to Electric Vehicles (EVs), the operating speeds of prime movers have significantly increased. Commercial EV manufacturers prefer high-speed, low-torque motors coupled with transmissions over low-speed, high-torque motors due to higher efficiency and power density. This combination of high-speed, low-torque motors coupled with transmission is essential for achieving the required gradeability and enhances operational efficiency. However, the increased operating speeds of these EV transmissions have inherently increased the risk of ‘bearing creep’ [8]. The “bearing creep” is the phenomenon where unintended relative motion occurs between bearing races and their mounting surfaces, leading to premature wear of mounting surfaces [3]. This issue can lead to a series of failure modes such as increased gear mesh misalignment, bearing damage, seal damage, etc. These problems result into elevated transmission vibrations eventually
Bagad, Sachin Sunil, Kanase, Ashish, Hiremath, Satalingayya, Nevarekar, Sandip
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