Browse Topic: Manufacturing processes
For years the NVH community has known that openings in the dash sheet metal, such as holes to pass wire harnesses through, creates an acoustical weak point that limits the potential noise reduction of the dash insulation system. These pass-throughs can also be a source of water leaks into the vehicle’s interior. With internal combustion engines and now electric inverter power plants generating significant high frequency sound, the need to seal this area is vital. By molding a lightweight barrier that draws through the fiber/absorber interior decoupler and dash sheet metal which mates to a secondary seal molded into an outer engine dash decoupler, the two opposing molded barriers meet in the engine compartment and compress together forming a seal around the wire harness. This male/female molded seal replaces the conventional snap in grommet and eliminates noise/water leaks. The system Sound Transmission Loss (STL) is equivalent to similarly insulated sheet metal with no holes
This article follows a companion article [1] presented at the SAE NVC 2021, in which a new system for the measurement on small samples of the normal-incidence Insertion Loss (IL) of multilayers used for the manufacturing of automotive sound package parts was first introduced. In addition to simplifying the evaluation of the sound-insulation of multi-layers used to produce sound-package components, the system aims at overcoming the limitations of the test procedure based on the ASTM E2611 standard. In this article, the latter point is demonstrated by comparing the insertion loss results obtained with the new system with those obtained with the test procedure based on the ASTM E2611 standard on a few multilayers commonly used for the manufacturing of automotive sound package parts. Results indicate that the data obtained by means of the newly developed system are more meaningful, practically usable and less prone to edge-effects, compared to those obtained according to the ASTM E2611
The segment manipulator machine, a large custom-built apparatus, is used for assembling and disassembling heavy tooling, specifically carbon fiber forms. This complex yet slow-moving machine had been in service for nineteen years, with many control components becoming obsolete and difficult to replace. The customer engaged Electroimpact to upgrade the machine using the latest state-of-the-art controls, aiming to extend the system's operational life by at least another two decades. The program from the previous control system could not be reused, necessitating a complete overhaul.
Climate-neutral aviation requires resource-efficient composite manufacturing technologies and solutions for the reuse of carbon fibers (CF). In this context, thermoplastic composites (TPC) can make a strong contribution. Thermoforming of TPC is an efficient and established process for aerospace components. Its efficiency could be further increased by integration of joining processes, which would otherwise be separate processes requiring additional time and equipment. In this work, an integrative two-step thermoforming process for hollow box structures is presented. The starting point are two organosheets, i.e. fiber-reinforced thermoplastic sheets. First, one of the organosheets, intended for the bottom skin of the uplift structure, is thermoformed. After cooling, the press opens, the organosheet remains in the press and an infrared heater is pivoted in, to locally heat up just the joining area. Meanwhile, a second organosheet, intended for the top skin, is heated and thermoformed and
The mass production of conventional silicon chips relies on a successful business model with large “semiconductor fabrication plants” or “foundries.” New research by KU Leuven and imec shows that this “foundry” model can also be applied to the field of flexible, thin-film electronics. Adopting this approach would give innovation in the field a huge boost.
MEMS is a more complex technology than traditional semiconductors. They are 3D structures with moving parts, making them much more difficult to fabricate. If you’re designing a semiconductor, you may be able to take advantage of an existing process development kit (PDK), which your foundry can provide to you. There is no equivalent approach in MEMS. It’s a “one process, one product” paradigm that requires a high level of customization. That takes time, money, and resources.
This specification covers procedures for sampling and testing aircraft-quality, special aircraft-quality, and premium aircraft-quality steels requiring transverse tensile property testing.
This specification defines the procedures and requirements for joining metals and alloys using the electron-beam welding process.
This SAE Aerospace Standard (AS) defines the requirements for a convoluted polytetrafluoroethylene (PTFE) lined, metallic reinforced, hose assembly suitable for use in aerospace fluid systems at temperatures between -65 °F and 400 °F for Class 1 assembly, -65 °F and 275 °F for Class 2 assembly, and at operating pressures per Table 1. The use of these hose assemblies in pneumatic storage systems is not recommended. In addition, installations in which the limits specified herein are exceeded, or in which the application is not covered specifically by this standard, shall be subject to the approval of the procuring activity.
3D-printed microscopic particles, so small that to the naked eye they look like dust, have applications in drug and vaccine delivery, microelectronics, microfluidics, and abrasives for intricate manufacturing. However, the need for precise coordination between light delivery, stage movement, and resin properties makes scalable fabrication of such custom microscale particles challenging. Now, researchers at Stanford University have introduced a more efficient processing technique that can print up to 1 million highly detailed and customizable microscale particles a day.
Mesekon Oy, a Finnish welding manufacturer that produces complex welded steel structures for the marine, energy, and paper industries, needed a flexible and collaborative solution to improve efficiency, reduce defects, and enhance workplace ergonomics by automating repetitive and physically demanding welding operations.
Since the early 1980s, the automotive industry has used hydraulically actuated (servo-hydraulic) test systems to simulate operating speeds and road conditions for testing OEM components and fully assembled vehicles. They have helped unlock vast improvements in the quality, safety, and reliability of the cars and trucks coming off the world’s assembly lines.
Purdue University material engineers have created a patent-pending process to develop ultrahigh-strength aluminum alloys that are suitable for additive manufacturing because of their plastic deformability.
The initial powder used for the manufacturing of NdFeB permanent magnets is usually prepared through rapid cooling, either by melt spinning or strip casting. The powders produced by these two methods are suitable for different applications: while melt-spun powder is a good initial material for bonded and hot-deformed magnets, strip-cast powder is normally used for sintered magnets. To investigate the suitability of using strip-cast powder to manufacture hot-deformed magnets, NdFeB powder prepared by strip casting was hot pressed (without particle alignment) and compared with melt-spun powder prepared under the same conditions (700 °C, 45 MPa, 90 min). Although the processing parameters are the same (pressed in the same mold), the magnetic properties of the magnets made from the two powders are significantly different. Surprisingly, the magnet made from the strip-cast powder (after ball milling) shows comparable magnetic properties to those of isotropic magnets, with coercivity (HcJ) of
To promote the electric performance and safety of development for EV mobility, optimization methodology and design guide of high voltage bolted joint should be newly developed. This paper describes the development process of multi-physics (electrical, mechanical, thermal) FEA methodology, various experimental tests and establishment of optimization methodology of busbar bolted joint design in terms of bolt preload validation and joint temperature rise. The various key factors on high voltage joint tightening are quantitatively studied by utilizing this optimized methodology.
Battery cell aging and loss of capacity are some of the many challenges facing the widespread implementation of electrification in mobility. One of the factors contributing to cell aging is the dissimilarities of individual cells connected in a module. This paper reports the results of several aging experiments using a mini-module consisting of seven 5 Ah 21700 lithium-ion battery cells connected in parallel. The aging cycle comprised a constant current-constant voltage charge cycle at a 0.7C C-rate, followed by a 0.2C constant current discharge, spanning the useful voltage range from minimum to maximum according to the cell manufacturer. Charge and discharge events were separated by one-hour rest periods and were repeated for four weeks. Weekly reference performance tests were executed to measure static capacity, pulse power capability and resistance at different states of charge. All diagnostics were normalized with respect to their starting numbers to achieve a percentage change
Items per page:
50
1 – 50 of 22821