Browse Topic: Manufacturing processes

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First Time Quality as an Indicator for Quantifying the Impact of Software Updates in Automotive Production2026-01-0786To be published on 07/01/2026
Vehicle software updates are released more frequently and in increasingly shorter cycles, which places growing pressure on vehicle quality and final assembly line stability. In production environments, software related issues do not remain limited to the digital domain, since errors introduced by software updates can interrupt flashing and commissioning processes, slow down assembly, and increase rework, thereby directly affecting production throughput. Electronic control units (ECUs) are particularly sensitive to software updates because they are flashed and commissioned during vehicle production under strict timing constraints, and changes to flashing sequences, memory structures, configuration parameters, or function definitions can negatively influence commissioning behavior. This paper shows that the impact of software updates on vehicle production can be quantified in a data-driven manner using First Time Quality (FTQ) as an impact measure. FTQ refers to the percentage of ECUs
El Asad, Aiman, Köhler, Katja, Hahn, Michael, Reuss, Hans-Christian
Improving reliability of an automotive power electronic unit using Locally Resonant Metamaterials2026-01-0701To be published on 06/20/2026
The shift from internal combustion to electric vehicles necessitates addressing new challenges posed by novel components, materials, manufacturing processes and different operating regimes. This includes assessing new types of excitations and damages from a reliability perspective. This paper investigates a solution to enhance the reliability of the Printed Circuit Board (PCB) within a Power Electronic Unit (PEU). PCBs are critical electronic and mechanical supports for functional components (e.g. diodes, transistors, resistors) in numerous applications. Controlling critical vibration levels is crucial to prevent electronic component breakage and subsequent PEU functionality loss. Existing solutions often focus on improving sensor-PCB bonding, surface treatments, or stiffening components’ support structures. The proposed approach, instead, exploits Locally Resonant Metamaterials (LRMs) to reduce the vibrational load experienced by the PCB. LRMs are created by adding resonating elements
Tincani, Sara, Claeys, Claus, Deckers, Elke, Pandiya, Nimish, Dindorf, Christian
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
Design of Acoustical Features for a Quitter Aero-Engine Test Facility2026-26-0787To be published on 06/01/2026
It is a general practice to test aero engines to evaluate their performance in specially designed indoor test facilities after assembly, repaired or overhaul. Acoustic features are provided in the test facility to attenuate the noise level to a comfortable and acceptable level. Design of these features specially air intake and exhaust silencers are a challenging task in a flow field like aero-engine test facility considering the very high sound pressure level generated by them during test containing a very wide frequency band. Moreover, growing population and location of these facilities in the vicinity of residential areas has added this challenge in multifold. Also, the capital investment in building these facilities is huge due to their large size and longer construction time. Hence, the correct execution at first shot including design, fabrication and commissioning is very important. An attempt has been made to reduce design errors or improve the accuracy in the design stage by
Gouda, Bansidhar
Evaluation of Thermal Behaviour of Ramie Fiber/Delrin Composites for Aircraft Cabin Components2026-26-0754To be published on 06/01/2026
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, Thirumalvalavan, Senthilkumar, N., Selvarasu, S
Design and Multi-Faceted Validation of UAV Arm Clamps, Landing Gear and Motor Mounts via Generative Design in Autodesk Fusion 3602026-26-0734To be published on 06/01/2026
This study presents a comprehensive methodology for optimizing critical UAV structural nodes—specifically Arm Clamps, Landing Gear, and Motor Mounts—using Generative Design (GD) tailored for Fused Filament Fabrication (FFF) with PLA+. Traditional “plate-and-standoff” UAV constructions often utilize orthogonal geometries that induce stress concentrations and fail to leverage the geometric freedom of additive manufacturing. Furthermore, reliance on expensive CNC machining or injection molding creates supply chain bottlenecks for custom or short-run UAV production. While FFF offers geometric freedom, applying it to structural airframe parts introduces challenges regarding anisotropy, layer adhesion, and material brittleness. This research optimizes these components for standard commercial 3D printers by strictly enforcing manufacturing constraints, including a 40-degree maximum overhang and a 0.4 mm nozzle size, to ensure printability without internal support structures. A significant
Krishna Bansal, Vaibhav
Predictive Model and Analysis of the Resultant Force in the Dry Machining of Mg-4Zn/Si 3 N 4 Nanocomposites2026-26-0762To be published on 06/01/2026
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, Anand, Shaju, Tony M, G, Nagamalleswara Rao, D, Bijulal, K, Jayaprakash Reddy, K, Vijayan, Chaman, Joji J
Mitigating Cracking in COP Optics through Annealing and Step-Torquing2026-26-0764To be published on 06/01/2026
Polymeric optical materials such as Cyclo Olefin Polymer (COP) are adopted in aerospace lighting systems due to their excellent optical clarity, dimensional stability, moldability and weight saving advantages over glass. However, their relatively low toughness and the presence of residual molding stress make them prone to crack initiation during mechanical fastening. During its installation, crack formation was consistently observed around self-tapping screw interfaces, raising concerns over reliability, maintainability, and compliance with durability requirements. A structured Design of Experiments (DOE) was performed to identify root causes and evaluate potential mitigation methods. The investigation revealed that residual stresses in the COP material, combined with localized stress concentrations during screw tightening, were the primary drivers of crack initiation. Two complementary process improvements were identified and validated as part of mitigation plan: (i) annealing of the
S, Nikhil, Singh, Abhimanyu Kumar, Katageri, Praveen, SP, Pradeep, Chandra, Praveen
Agentic Digital Thread for Managing the Non-Conformities in Manufacturing of Aerospace Products2026-26-0763To be published on 06/01/2026
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, Sastry, Gopala Krishnan, Kannan
Drilling Studies on Sustainable Lightweight Hybrid Polymer Matrix High-Performance Nanocomposites2026-26-0732To be published on 06/01/2026
Worldwide, engineers are exploring the possibility of using polymer composites in their quest for lightweight materials. In this study, injection moulding was used to develop a biodegradable polymer PLA composite containing 20 wt.% vetiver fibers (VFs) and 2 wt.% nano-silica (nSiO2) obtained from pearl millet, which is sustainable. Materials need machining as secondary operation that required joining. Desirability analysis was used to examine and optimize machining (drilling) studies that were designed with Taguchi's design (L9 orthogonal array). Surface roughness (SR) and delamination factor (Fd) were taken as outputs, while spindle speed (SS), feed rate (FR), and drill diameter (DD) were the inputs. Drilling studies were performed on a single vertical machining center (VMC). ANOVA identifies that the FR had the most decisive influence on SR (F=559.24, p=0.001785), followed by DD and SS. FR is the dominant contributor to Fd (F=379, p=0.00263), followed by SS and DD. At low SS and high
Senthilkumar, N.
Wear Resilience Characteristics of Silicon Nitride Strengthened AZ31 Magnesium Composite2026-26-0740To be published on 06/01/2026
To develop magnesium matrix composites, ceramic silicon nitride (Si3N4) particles are added to the magnesium (AZ31) matrix at 2 wt.%. The composite is produced via disintegrated melt deposition vacuum-stir-casting procedure. Microstructural studies reveal the presence of Si3N4 particles and their uniform spreading. An L9 orthogonal array, planned using Taguchi’s experimental design, is selected for three wear parameters; axial load (AL), rotational speed (RS), and time duration (TD) with trials as per the G99 standard in the pin-on-disc apparatus to assess the wear resilient of the composite. Experimental results show an increase in axial stress, and wear loss (WL) increases dramatically. Because the area of contact shrinks as RS increases, WL diminishes dramatically. When the AL is low, the friction coefficient (CoF) increases, and when the AL is large, CoF drops. When the RS is increased, CoF decreases. To optimize multiple responses effectively, the TOPSIS (Technique for Order
Senthilkumar, N., Dhinakar Raj, C K
Zero Waste Manufacturing in Aerospace: Circular Design Approaches from Concept to End-of-Life2026-26-0775To be published on 06/01/2026
Achieving zero-waste manufacturing in aerospace requires a shift from end-of-pipe waste mitigation toward circular design principles embedded early in product development. This paper presents a practical framework for integrating circularity into aerospace systems through five design pillars: design for modularity and disassembly, material substitution to enhance recyclability, waste segregation and characterization, component-level circularity readiness scoring, and collaborative supplier engagement. To operationalize this approach, a Circularity Readiness Assessment Tool (CRAT) is developed to evaluate design alternatives against criteria such as disassembly ease, material recyclability, manufacturing waste potential, end-of-life recovery pathways, and supplier take-back mechanisms. The framework supports multi-criteria decision-making by complementing traditional aerospace design drivers including weight, performance, cost, and safety. The methodology is demonstrated through a case
S, Chaitra
Reducing Test Campaigns through Advanced Yield Surface Modeling for New Aircraft Metal Grades2026-26-0755To be published on 06/01/2026
Qualification of new aerospace alloys requires extensive mechanical testing to capture anisotropy and ensure reliable performance under complex loading conditions. This process is costly and time-consuming, particularly with emerging manufacturing routes such as additive manufacturing. Advanced yield surface prediction offers a route to reduce test campaigns by linking microstructural features to macroscopic constitutive models. In this work, Digimat is employed as a multi-scale material modeling platform to generate yield surfaces of polycrystalline metals using computational homogenization. Representative volume elements (RVEs) are constructed from experimental texture and grain morphology data, and their response under multiaxial loading is simulated using a crystal plasticity framework. The computed yield loci are then fitted with phenomenological functions (e.g. Yld2000-2D), enabling calibration of anisotropic yield models from virtual testing. As a case study, an AA6016-T4 sheet
Padhan, Manas, Uppaluri, Rohith, Lemoine, Guerric, Soni, Ganesh
Occupant Sex Equity and Vehicle Safety: Historical Activities, Research, and Countermeasure2026-22-00025/28/2026
Since 2019, sex equity in traffic crashes has been a highly debated topic in vehicle safety, especially following the 2019 study by Forman et al. (1) claiming that female occupants face a 73 percent greater risk of serious injury in frontal crashes compared to male occupants. This was soon followed by a Consumer Reports Article by Keith Barry (2), which attempted to identify underlying factors contributing to the higher risk. These have been embraced by several parties since 2019. Firstly, it was alleged that vehicle design practice over the last four decades considered safety for the male population only and ignored that of the female as evidenced by the exclusive use of the mid-sized male Anthropomorphic Test Devices (ATDs) in Regulatory and Safety Ratings tests and not with an average sized female ATD. The absence of such an ATD for testing of vehicles “set the course for four decades’ worth of car safety design, with deadly consequences” (2). Secondly, although there is a
Prasad, Priya, Dalmotas, Dainius J.
Fabrication of Ultrathin Polyimide Optical Filter Films2026-99-17115/22/2026
Polyimides are a class of polymers with imide rings in their main chains. They are renowned for their exceptional mechanical properties, high-temperature resistance, low-temperature endurance, and resistance to chemical solvents, which allow for long-term use under harsh medical operating conditions. Consequently, research on polyimide films has garnered widespread attention. In this study, a two-step method was employed to simplify and optimize the preparation process of polyimide. Initially, a polyamic acid (PAA) solution was prepared, and PAA films were fabricated using a spin coater. Subsequently, the films were imidized to obtain polyimide (PI) films. The impact of various parameters, such as spinning speed, layer number, and temperature, on the film-forming properties of polyimide was investigated using the method of controlling variables. The findings indicate that by setting the spin coater parameters to 700 revolutions per minute (r/min) for 90 seconds, followed by a
Huang, Jiehao, Xu, Zihui, Zhao, Kaihong, Lin, Qiting, Hu, Wenzhong, Wang, Liying
COLUMBIUM ALLOY BARS, RODS, AND EXTRUSIONS 10Hf - 1.0Ti Recrystallization AnnealedAMS7857A (Current)5/20/2026
This specification covers a columbium alloy in the form of bars, rods, and extrusions.
AMS G Titanium and Refractory Metals Committee
Cabbage Cleaning Device Based on Fischertechnik Model2026-99-07345/15/2026
This article focuses on the problem of high labor cost, low processing efficiency and poor automation of the existing equipment in the postharvest processing of Chinese cabbage. It will design and produce an automated Chinese cabbage processing method called Smart Fresh Pack. Root removal, leaf removal, washing, loading, weighing, packaging and labeling functions were integrated, and smart dexterous intelligence was applied to core concepts and this can be used in the bulk production scenario of supermarkets in the city and countryside Compared with traditional assembly line equipment, obvious advantages in terms of structure, function and processing capacity: Key innovations include: Low-pressure air jet cleaning replaces water washing, which prevents a second contamination and weighing error due to surface moisture; pneumatic gripper and multi-DOF robotic arms combine to package and dynamically weigh simultaneously, streamlining these tasks; machine vision relies on an SSD
Chen, Yuhui, Zhang, Yixuan, Ruan, Jia, Zhu, Huayun, He, Lianzheng, Zhao, Ping
Evaluation of Mechanical Tensile Properties on TIG-Welded AISI 304L Austenitic Stainless Steel Using Principal Component Analysis05-19-04-00275/14/2026
The reliability of welded joints is a vital factor in modern manufacturing, directly affecting product performance and durability. This study investigates methods to enhance the mechanical and metallurgical quality of butt joints in AISI 304L stainless steel welded by the gas tungsten arc (GTA) process. A systematic experimental design was implemented using the Taguchi method with an L9 orthogonal array, considering welding current, gas flow rate, and travel speed as the main parameters. To determine overall weld performance, the joints were characterized by measuring ultimate tensile strength (UTS), yield strength, percentage elongation, and examining their microstructural morphology. An experimental strategy based on the Taguchi approach has been implemented. The welding performance of the material was investigated, and the process parameters were optimized using multiresponse optimization through principal component analysis (PCA), incorporating an orthogonal array design, signal-to
Ghosh, Nabendu, Roy, Angshuman
An Analytical Piecewise-Linear Joint Stiffness Model for Predicting Load Distribution in Multi-Bolt Metal–Composite Joints05-19-04-00285/14/2026
Accurate prediction of load distribution in multi-bolt metal–composite joints relies heavily on high-fidelity modeling of single-bolt joint stiffness. Current models, however, inadequately capture the complex effects of bolt–hole clearance, including delayed load take-up and reduced bearing chord stiffness, as well as multi-interface friction interactions. To overcome these limitations, quasi-static tests were conducted on single-bolt, single-lap aluminum–CFRP joints with varying clearances. By integrating experimental findings with an analysis of the load-transfer mechanisms, we identified five distinct loading states and formulated corresponding analytical load-deformation equations along with explicit transition criteria, culminating in a novel piecewise-linear stiffness model. Enhancements over traditional tri-linear models encompass: (a) subdivision of the transition region into separate local and global slip phases, facilitating an accurate representation of asynchronous slip
Liu, Haolong, Sun, Qingping, Liu, Yang, Zhao, Qi, Liu, Yue
SAE TOMORROW TODAY - Why Curing Motion Sickness Is Key to AV Success135675/11/2026
Did you know that motion sickness affects 1 in 3 people? As AVs gain traction and drivers become passengers, it may be the biggest barrier to the future of autonomous mobility. With a focus on addressing the root cause of motion sickness, Motion Sync offers breakthrough solution: a haptic pre-activation system that helps passengers anticipate vehicle movement with a personalized in-cabin experience that could redefine comfort and productivity. Listen in as we sit down with Dr. Daniel Sousa Schulman, CEO and Founder of Motion Sync, to unpack the science behind motion sickness and why it's a critical issue for EVs, robotaxis, and self-driving cars. You'll learn why passengers get sick, why drivers don't, and how EVs can actually make symptoms worse. As a topic critical to the success of autonomous vehicles, it's a conversation you don't want to miss. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take
Patterson, Lori
Unidirectional Carbon Fiber Tape Epoxy Repair Prepreg, Vacuum Curing Part 4 - Purchasing Specification for Film AdhesiveAMS6885/4 (Current)5/7/2026
This Purchasing Specification, AMS6885/4, specifies the batch release and delivery requirements for film adhesive used for repair. This specification is applicable only when the film adhesive is used as part of the repair system defined in AMS6885 and AMS6885/1. This specification also defines the procedure and requirements for storage life extension of materials purchased against this specification. It is only applicable for materials qualified against AMS6885 (refer to PRI-QPL-AMS6885), and shall be carried out within the responsibility of the purchaser and under control of its Quality organisation.
AMS CACRC Commercial Aircraft Composite Repair Committee
Unidirectional Carbon Fiber Tape Epoxy Repair Prepreg, Vacuum Curing Part 3 - Purchasing Specification for Unidirectional Carbon Fiber Tape Epoxy Repair PrepregAMS6885/3 (Current)5/7/2026
This Purchasing Specification, AMS6885/3, specifies the batch release and delivery requirements for unidirectional carbon fiber tape epoxy prepreg used for repair. This specification is applicable only when the unidirectional carbon fiber tape epoxy prepreg is used as part of the repair system defined in AMS6885 and AMS6885/1. This specification also defines the procedure and requirements for storage life extension of materials purchased against this specification. It is only applicable for materials qualified against AMS6885 (refer to PRI-QPL-AMS6885) and shall be carried out within the responsibility of the purchaser and under control of its Quality organisation.
AMS CACRC Commercial Aircraft Composite Repair Committee
How Machina Labs is Reshaping Defense Manufacturing with AI-Driven 7-Axis Robotics26AERP05_015/1/2026
Machina Labs recently closed its latest round of financing with $124 million, enough to develop a facility featuring up to 50 of its RoboCraftsman cells capable of producing thousands of complex structural assemblies for aerospace and defense customers - a list that already includes Lockheed Martin and the U.S. Air Force, among others. Founded in 2019, Machina Labs is a California-based company that seeks to reinvent metal manufacturing with a robot that uses artificial intelligence (AI) to rapidly form and assemble complex military grade structures directly from digital design files. RoboCraftsman is the company's manufacturing robot that leverages its proprietary “RoboForming” process to integrate multiple manufacturing processes - including metal forming, trimming, scanning, and heat treating - into a single containerized machine.
Paste Adhesive for Core Restoration Part 1 - General RequirementsAMS2950/1 (Current)4/28/2026
This Technical Specification gives information about technical requirements and qualification procedures of adhesive paste with or without thickening agent for core restoration of aircraft components.
AMS CACRC Commercial Aircraft Composite Repair Committee
Investigation of Metallurgical and Mechanical Behaviors of AA6061-AA2017 Joints Produced by Single- and Double-Pass Friction Stir Welding: Influence of Base Material Position and Post-Weld Shot Peening Technique05-19-04-00264/13/2026
The growing demand for lightweight, high-strength materials in marine and aerospace structures has promoted the use of friction stir welding (FSW) for welding dissimilar aluminum alloys. However, tensile residual stresses and microstructural heterogeneities often degrade weld integrity. This study investigates the combined impact of base material positioning, single- and double-pass FSW, and post-weld shot peening (SP) on the metallurgical and mechanical properties of AA6061–AA2017 joints. Five welding configurations were examined to evaluate how varying base material positions on the advancing and retreating sides affect material flow and mechanical behavior. Post-weld SP effectively presented compressive residual stresses, reduced surface defects, and refined surface grains. The average grain size in the stir zone was reduced from 5.2 μm (single-pass) to 2.0 μm (double-pass U-turn) after SP, confirming significant grain refinement through dynamic recrystallization. Mechanical testing
Nukathoti, Raja Sekhar, Battina, N. Malleswara Rao, Vanthala, Varaha Siva Prasad, Chirala, Hari Krishna, Maloth, Balu
Steel, Corrosion-Resistant, Bars, Wire, Forgings and Forging Stock, 18.5Cr - 10Ni - 0.22Se (303Se), Free-Machining; for Swaging or Upsetting, Solution Heat TreatedAMS5641K (Current)4/12/2026
This specification covers a free-machining, corrosion-resistant steel in the form of bars, wire, forgings, and forging stock.
AMS F Corrosion and Heat Resistant Alloys Committee
Role of Advanced Polishing Techniques in Enhancing Al-Cu Diffusion Bonding for EV Application2026-01-02354/7/2026
The demand for lightweight, high-efficiency components in electric vehicles (EVs) highlights the critical need for reliable Al-Cu joints with superior electrical and thermal conductivity. While diffusion bonding has emerged as a promising approach, interfacial impurities and voids often degrade joint quality and conductivity. Conventional manual polishing was initially employed to prepare Cu and Al surfaces; however, this method proved insufficient in consistently removing oxides and contaminants, leading to non-uniform bonding. In addition, the larger surface area of the samples made traditional polishing impractical, further motivating the use of electropolishing. To overcome these limitations, we introduce electropolishing pretreatment to achieve cleaner, void-free interfaces. Electropolishing effectively dissolves surface asperities and contaminants, enabling intimate atomic contact during bonding and minimizing the formation of brittle intermetallic phases. A systematic
Abbasi, Hossein, Liu, Yi, xiao, Yaohong, Wang, Andy, Su, Jinrong, Wang, Qigui, Chen, Lei
Strain-Based Fracture Assessment of Tailor Welded Blanks under Complex Loading Conditions2026-01-02314/7/2026
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
Integrated Welding Simulation and Experimental Characterization of Weld-Metal and Heat-Affected-Zone Strength in AA6063-T62026-01-02304/7/2026
In the context of automotive lightweighting and efficient manufacturing, welding is a key joining method for aluminum body structures due to its maturity, versatility, and cost effectiveness. This study investigates MIG butt welding of AA6063-T6 sheets using a sequential thermo-mechanical finite element model with a double-ellipsoid heat source. Thermocouple histories and macroscopic metallography of the weld-pool morphology are used to validate the predicted temperature field, and post-weld deformation measured by a coordinate measuring machine is compared with the simulation to confirm overall model reliability. Hardness mapping across the joint partitions the material into weld metal (WM), heat-affected zone (HAZ), and base metal (BM). Miniature tensile specimens extracted along the weld provide local mechanical properties, from which linear strength–hardness relations are established. Building on these results, a five-material equivalent strength model covering WM, HAZ-I, HAZ-II
Shao, Jiyong, Meng, Dejian, Xiang, Yao, Gao, Yunkai
Effective Prediction of the Mechanical Properties of Glue-Laminated Motor Stator Core with Consideration of Glue Disposition2026-01-01774/7/2026
This study presents an effective predictive methodology for determining the mechanical properties of glue-laminated motor cores, with explicit consideration of glue disposition, including bonding pattern, configuration, location, and coverage. In laminated stator cores, glue bonding and stacking processes jointly govern the mechanical integrity of the lamination stack. Practical production bonding schemes are typically nonuniform and localized, leading to spatial variations in stiffness and to locally anisotropic, orthotropic material behavior. These effects influence both the in-plane and through-thickness stiffness of the stator core. They can significantly affect the accuracy of structural simulations, such as NVH responses of high-speed traction motors and e-drive systems. Given the constituent material properties of the electrical steel laminations and the glue, this work distinguishes the governing mechanisms underlying the equivalent core properties. The in-plane stiffness is
Nie, Zifeng
Artificial Intelligence in Automotive Stamping – The Latest Industrial Applications and Future Directions2026-01-01794/7/2026
A review of the applications of Artificial Intelligence (AI) in automotive stamping is presented. The focus is on recent AI implementations within the automotive industry. Through this review, the authors aim to capture the current momentum of AI in automotive stamping. The article begins with an overview of the importance and challenges of stamping in the automotive sector, followed by a discussion of key AI technologies applied in this domain. Several industrial applications are then introduced, categorized by their specific use cases. Finally, strategic challenges and future directions are discussed.
Sheng, ZiQiang, Huang, Lu, Asimba, Brian, McCarty, Eric, Whaley, Jason, Cabral, Kleber, Osegueda, Mario, Huang, Xiaosong, Erol, Baris
WITHDRAWAL NOTICE2026-01-0492.014/7/2026
Adhesion Strength of Coatings in Battery Structural Joints2026-01-02384/7/2026
In the design of Rechargeable Energy Storage System (RESS) structures, including battery trays, module side plates, and end plates, there are multiple conflating factors, including: Mechanical requirements necessitating the use of electrically conductive materials (steel and aluminum); proximity between battery module structure and battery cells, necessitating the use of electrical isolation coatings; and, module and pack designs that retain cells via the use of Structural Adhesive Material (SAM). Inherently, with this design approach, organic coatings are placed in a new and perilous position. In a sense, the coating becomes a supplement to an adhesive. As Computer-Aided Engineering (CAE) virtual analysis tools become more sophisticated, there is increasing reliance on these tools to predict the occurrence of structural failures in various load cases. Factors in test method, paint pretreatment, and topcoat affecting adhesion of organic coatings in structural adhesive joints are
Moceri, Charles, Harper, Jared
Development of Automotive Hood Using Multi-Material Double Injection Molding – An Overview2026-01-04764/7/2026
This paper presents the multidisciplinary development of a hybrid automotive hood manufactured using double-shot injection molding with overmolded brackets. Conventional steel and aluminum hoods, while structurally reliable, pose challenges in terms of weight reduction, pedestrian head protection, and manufacturing cost. Composite and thermoplastic alternatives supported by computational analysis and advanced molding processes provide opportunities to address these challenges. Finite element analysis (FEA) was employed to evaluate torsional and bending stiffness, locking load, and crashworthiness, while pedestrian headform simulations following ECE R127 and EEVC WG17 guidelines were conducted to assess compliance with safety regulations. Adhesion and bonding strength of overmolded polymer–polymer interfaces were studied to validate manufacturing feasibility. Results confirm that hybrid hoods fabricated using multi-material double-shot molding can achieve weight reductions of up to 30
Ganesan, Karthikeyan, Seok, Sang Ho, Jo, Hyoung Han
Kissing Bonds Inspection by Comparing Natural Frequencies Using Digital Holography2026-01-02074/7/2026
Accurate detection and evaluation of kissing bonds in composite materials is essential to ensure the integrity of the component structure, but traditional NDT (non-destructive testing) methods struggle to identify imperfect bonds and zero-volume debonds. In this study, a vibration analysis method based on holography was applied to detect kissing bonds by monitoring the changes in natural frequencies of the same sample before and after fatigue loading. Both pristine and kissing bond samples were tested under identical conditions, and their vibration characteristics (natural frequency, amplitude, and mode shape) were measured using holography. The experimental results show for the intact sample exhibited no changes in natural frequency amplitude or mode shape after fatigue loading, confirming that the applied fatigue test did not affect the integrity of its adhesive layer. In contrast, for the sample with a kissing bond, after fatigue loading, the natural frequency decreased by up to 22
Gao, Zhongfang, Fang, Siyuan, Gerini-Romagnoli, Marco, Yang, Lianxiang
A Novel Spot Joint Finite Element for Rapid Stress Analysis of Fasteners in Automotive Structures2026-01-01824/7/2026
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
A Study on Fatigue Life Prediction Method for Point-Based Joints Considering Multiple Fracture Modes – FDS, Blind Rivet, and Blind Nut Focus2026-01-01804/7/2026
The application of multiple materials in vehicle bodies is accelerating as the adoption of lightweight aluminum alloys and composite materials advances rapidly. These materials play a crucial role in reducing overall vehicle weight, enhancing fuel efficiency, and complying with increasingly strict environmental regulations. As the automotive industry continues to evolve toward electrification and sustainability, the integration of lightweight and high-performance materials has become a key design strategy. However, the use of multiple materials creates new challenges in manufacturing, particularly for joining technologies. Since different materials have varying mechanical properties, thermal behavior, and surface characteristics, the selection of appropriate joining methods is essential for ensuring structural integrity and durability. Depending on material types, thicknesses, production processes, and cost constraints, various joining techniques—such as mechanical fastening, welding
Takuno, Sougo, Isono, Toshiyuki, Urakawa, Kazushi, Goto, Suguru, Kawamura, Hiroaki, Niisato, Eita, Ishigami, Yuta
Anisotropic Mechanical Property Simulation of Fiber Reinforced PEEK Using Composite Theory and Comparison to Experimental Results2026-01-02564/7/2026
The mechanical properties of 3D printed composites have been shown to vary due to the manufacturing infill direction due to artifacts from the printing process. PEEK (Polyether Ether Ketone) and PEEK reinforced with carbon fiber were studied for these experiments because they are widely used for their high strength properties. 3D printed composites that behave with anisotropic characteristics have been evaluated under Laminate Composite Theory (LCT), which can be used to determine the mechanical properties of these 3D printed composites. By changing the orientation of the extruded strands in a 3D printed part, the structure can be optimized in a specific orientation for specific loading conditions, and LCT can be applied for simulating mechanical responses. Three point bending tests were performed on rectangular 3D printed samples and compared to a 3D simulation using LCT for a similar bending load. This allows for the use of LCT in combination with a finite element software such as
Bradley, Coilin, Garcia, Jordan, Sibley, Brian
Experimental Validation of a Multi-Row Tapered Roller Bearing Analytical Model for Relating Preload to Frequency Response Characteristics2026-01-00084/7/2026
Roller bearings are used in many rotating power transmission systems in the automotive industry. During the assembly process of the power transmission system, some types of roller bearings (e.g., tapered roller bearings) require a compressive preload force. Those bearings' rolling resistance and lifespan strongly depend on the preload set during the installation process. Therefore, accurate setting of the preload can improve bearing efficiency, increase bearing lifespan and reduce maintenance costs over the life of the vehicle. A new method for bearing preload measurement has shown potential for both high accuracy and fast cycle time using the frequency response characteristics of the power transmission system. An open problem is experimental validation of the multi-row tapered roller bearing analytical model. After validation, the analytical model can be used to predict the assembled system damped natural frequency for a desired bearing preload. This work presents the experimental
Gruzwalski, David, Mynderse, James
A Decision-Making Framework for Field Manufacturability of Vehicle Parts in Expeditionary Environments2026-01-01434/7/2026
Expeditionary environments (such as remote exploration missions, forward military operations, and disaster response zones) demand adaptive manufacturing solutions to support vehicle sustainment in the absence of traditional supply chains. This work introduces a conceptual mathematical framework for modeling the constraints and tradeoffs inherent to expeditionary manufacturing, with a focus on vehicle repair and spare parts fabrication using low-energy and simple automated systems including desktop-scale 3D printers and CNC machines. The model integrates key variables such as energy availability, material transport cost, fabrication time, and environmental limitations to support rapid decision-making on part manufacturability and in-field feasibility. A case study involving the on-demand production of some common wear and failure parts on a vehicle, including suspension components and the water pump, is used to demonstrate how this framework can guide the selection of suitable
Mollan, Calahan, Pandey, Vijitashwa, Patterson, Albert E.
Optimizing Weld Placement in Automotive Structures Using Topology and Multi-Disciplinary Approaches2026-01-05144/7/2026
This work presents two approaches for weld optimization aimed at reducing manufacturing cost and process time, while meeting structural performance requirements in automotive structures. The first approach uses topology optimization to identify the most efficient weld layouts. A design space is generated along mating flanges, joints, and panel interfaces, where potential weld locations are defined. Welds are treated as discrete design variables, and the topology optimization systematically evaluates their contribution to global stiffness and load path integrity. Non-critical welds, those with minimal impact on stiffness, durability, or crashworthiness, are eliminated, resulting in a minimized weld pattern that maintains structural performance. The second approach applies Multi-Disciplinary Optimization (MDO) to balance weld reduction with performance targets across multiple domains, including linear and non-linear stiffness, crashworthiness, and fatigue. Using a preprocessing tool
Koppaka, Vinaya, Yoo, Dong Yeon, Chavare, Sudeep
High-Speed Flashing in the Age of the Software-Defined Vehicle2026-01-01124/7/2026
In recent years, the use of software-defined platforms has become increasingly prevalent. As a result, flashing ECUs has become an important factor in ensuring efficiency, quality, and compliance in vehicle production. Conventional approaches, such as final end-of-line flashing, are increasingly unsuitable for the growing amounts of data, complex dependencies, mixed physics and protocols, and traceability requirements. This SAE paper presents the current trends and challenges in ECU flashing. It highlights the impact of the exponential growth in software payloads and the necessary migration to offline and parallel workflows. This can only be achieved through closer integration with automated and robot-assisted production, considering the requirements of cybersecurity and verifiability. It also addresses the shift toward end-to-end flashing ecosystems, where updates are performed consistently from a single source covering the assembly line, warehouses, yards, workshops, and over-the-air
Böhlen, Boris, Budak, Oguz, Wells, Michael
Wind-Tunnel Investigation of Snow/Ice Drag on a 30%-Scale DrivAer Model2026-01-06044/7/2026
Wind-tunnel tests were conducted using a 30%-scale DrivAer model, in estateback and notchback rear-geometry configurations, to investigate aerodynamic performance changes associated with snow and ice buildup on passenger vehicles. Around 20 snow/ice accumulation patterns were tested, at a Reynolds number of 2.8 × 106 based on model wheelbase, for each of the notchback and estateback variants. 5 additional patterns were tested on the estateback with roof-rack support bars. Snow accumulation was modelled with foam, while ice accumulation was simulated with aluminum tape hand-formed to the desired shape. A simulated full-scale snow thickness of 58 mm on the hood, roof and trunk increased the wind-averaged drag coefficient by 16% for both model variants. With 90 mm of snow, the drag of the estateback variant increased by 19%. Drag changes increased with, but were not proportional to, snow thickness. Chamfered front and rear edges, representing windblown shapes, reduced the drag penalty
de Souza, Fenella, McAuliffe, Brian
Design Optimization and Dimensional Tolerance Improvement of Expanded Polypropylene (EPP) for Enhanced Automotive System Integration2026-01-02484/7/2026
Historically, EPP has required larger dimensional tolerances and much thicker cross-sections than solid plastics produced by injection molding, vacuum forming, and blow molding. This has proved challenging when attempting to incorporate EPP into a wider variety of automotive applications. JSP has developed multiple grades of EPP that achieve tolerances at thinner cross-sections, once considered difficult to attain. These grades expand the potential for automotive applications by combining the established benefits of EPP with improved dimensional precision. This tighter control enables advances in part design and performance, including reduced wall thicknesses, improved surface appearance, reduced weight, lower cost, part consolidation, and more efficient molding with an improved processing window, resulting in faster cycle times and reduced utility consumption. At the vehicle level, these improvements contribute to lighter overall weight for reduced carbon footprint, as well as
Sopher, Steven, Parker, Joshua
Multi-Objective Topology Optimization for Cost and Time Minimization in Fiber Reinforced Additive Manufacturing2026-01-02574/7/2026
Fiber Reinforced Additive Manufacturing (FRAM) combines the geometric freedom of additive manufacturing with the high stiffness-to-weight advantages of composite materials, making it a promising approach for lightweight automotive components. The mechanical performance of fiber-reinforced composites is strongly influenced by fiber orientation, which highlights the importance of optimization methods that can effectively exploit anisotropic behavior. Existing FRAM optimization research has focused primarily on structural performance and has given limited attention to manufacturability challenges. This gap is significant, as overhangs and the resulting need for support structures can substantially increase print time, material consumption, and production cost, restricting broader industrial uptake. This research introduces a multi-objective topology optimization framework that incorporates Design for Additive Manufacturing (DfAM) principles by minimizing both structural compliance and
Wotten, Erik, Kim, Il Yong
Comparison of Formability Performance Between CR550LA and CR590DP2026-01-01784/7/2026
While rapid development of advanced high strength steels (AHSS) for a safer and lighter vehicle has been a primary focus in the automotive industry, the application of traditional high strength low alloy (HSLA) steel continues to be actively supported and developed. AHSS are often used to replace HSLA steels for downgauging while maintaining similar or better performance in crashworthiness and durability. However, recent developments have enabled the availability of higher strength, cold-rolled HSLA steels that could offer opportunities for a more balanced solution between material cost and material performance. Certain higher strength HSLA steels not only offer a cost-effective way to increase the strength-to-weight ratio but also provide comparable formability and better weldability to AHSS. In this study, cold rolled HSLA grades of CR420LA and CR550LA are evaluated in overall formability and in-use performance when compared to CR590 dual phase (DP) grade. The evaluations performed
Shih, Hua-Chu, Brown, Lindsay, Pednekar, Vasant, Shi, Ming, Tedesco, Sarah
Development of an Advanced Tensile Testing Method for HDPE Composites in High Draw Molded Hollow Circular Regions: Effect of Sample Preparation, Asymmetry, Thermal Conditions, Pull Speeds and Fixture Parameters2026-01-02044/7/2026
High-Density Polyethylene (HDPE), Low-Density Polyethylene (LDPE) and Ethylene Vinyl Alcohol (EVOH) composite, particularly in high draw molded hollow circular configuration, present unique challenges in evaluating mechanical performance under tensile stress due to anisotropic deformation, geometric asymmetry, and localize thermal gradient. This study introduces an advanced tensile testing methodology designed specifically to assess such regions with greater precision and reproducibility. The method incorporates refines sample preparation protocols, tailored fixture geometry, and adjustable pull speed to accommodate varying thermal histories and draw ratios inherent to molded sections. Systematic variation of asymmetrical, temperature conditions, and clamping techniques revealed significant impact on tensile strength, elongation at break, and strain distribution. Findings emphasize the necessity of customized testing frameworks for molded composites geometries and demonstrate that
Bhalerao, Saurabh Shankar
Optimizing Joint Efficiency in Stainless Steel-Aluminum Alloy FSW Joints through Advanced Parameter Control2026-01-02284/7/2026
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
Investigation on Microstructure and Mechanical Properties in the Dissimilar Joining of WE43 to AA7075 Alloy using FSW2026-01-02294/7/2026
This research investigates the alterations in microstructure, microhardness, and joint strength resulting from the dissimilar friction stir welding (FSW) of WE43 magnesium alloy to AA7075 aluminium alloy. The study specifically analyses the role of FSW process parameters in the formation of intermetallic compounds (IMCs), the evolution of grain structure, the resultant microhardness distribution across the weld zone, and the joint tensile strength. A comprehensive microstructural characterization was performed utilizing optical microscopy (OM), field emission scanning electron microscopy with energy-dispersive X-ray spectroscopy (FESEM-EDS), electron backscatter diffraction (EBSD), and X-ray diffraction (XRD). These analyses confirmed significant grain refinement in the stir zone and the identification of various IMCs at the weld interface. Microhardness mapping indicated a gradient profile, with the weld nugget exhibiting superior hardness attributed to its dynamically recrystallized
Ahmad, Tariq, Khan, Noor Zaman, Ahmad, Babar, Siddiquee, Arshad Noor
Multi-Joint Topology Optimization Method with Interface Geometry Control2026-01-05034/7/2026
Topology optimization (TO) has become a reliable and lightweight design approach which was widely adopted in multiple industrial applications. Over the past decades, TO has advanced through three major development stages to increase its practicality and application scope: single-material topology optimization (SMTO), multi-material topology optimization (MMTO), and multi-joint topology optimization (MJTO). SMTO involves only one candidate material, whereas MMTO takes multiple candidate materials into consideration, which widen the application scope of TO. In terms of MJTO, it not only considers multiple candidate materials but also considers the bonding material between dissimilar candidate materials, improving practicality over MMTO. However, prior MJTO methods overlook the geometry of dissimilar material interfaces, a factor that may impact material bonding effect. In this paper, a novel MJTO algorithm is introduced to enable explicit control over interface geometry in MJTO. Central
Shi, Yifan, Huang, Yuhao, Kim, Il Yong
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