Browse Topic: Manufacturing processes

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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
Predictive model and analysis of the resultant force in the dry machining of Mg-4Zn/Si3N4 nanocomposites2026-26-0762To be published on 06/01/2026
In aerospace and automotive applications, the usage of magnesium (Mg)-based alloys and composites reduces the structural weight due to their low density. They also possess good specific strength and are abundantly available. The Mg-4Zn alloy is one such Mg-based alloy that is also biodegradable and biocompatible. 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 (also a biocompatible bio-ceramic) are hypothesized to possess superior properties. Sustainable machining with minimal subsurface defects and minimal energy consumption is necessary to manufacture components from these vacuum stir-cast nanocomposites. The resultant machining force (Fr) is a good indicator of subsurface quality and energy consumption in machining. The addition of Si3N4 reinforcement to improve the properties of the Mg-4Zn alloy could introduce challenges in machining and could influence Fr. To
N, Anand, Shaju, Tony M, G, Nagamalleswara Rao, D, Bijulal, K, Jayaprakash Reddy, K, Vijayan, Chaman, Joji J
Agentic Digital thread for self-healing non-conformities in aerospace product manufacturing lifecycle2026-26-0763To be published on 06/01/2026
Aircraft manufacturing involves a complex ecosystem where quality, traceability and compliance are paramount. Managing non-conformities both before and after manufacturing requires a digitally connected data framework that ensures seamless data flow, decision-making and corrective actions across different functions like sourcing, materials, engineering and production. The advent of agentic AI brings more autonomous solutions through drastically reduced human prompts. This paper presents a comprehensive Agentic Digital thread framework for managing pre and post manufacturing non-conformities, enabling real-time visibility and control from design to delivery. The Agentic digital thread transforms from being passive connectivity layer into living intelligence ecosystem that continuously learns, adapts, and improves in real time Pre-manufacturing nonconformity management focuses on early detection of issues through Agentic AI in sourcing, materials and design through integration of PLM
Veluri, Sastry, Gopala Krishnan, Kannan
Evaluation of Thermal and Thermo-Mechanical Behavior of Ramie Fiber/Delrin Composites for Aircraft Cabin Components2026-26-0754To be published on 06/01/2026
Abstract This study investigates the fabrication and evaluation of Delrin (polyoxymethylene, POM) composites reinforcing 5, 10, 15, and 20 wt.% chopped ramie fiber (RF). The polymer composites were fabricated via 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 thermo-mechanical and thermal characteristics of the composites that were systematically evaluated as per the ASTM standards. The Delrin matrix's performance was drastically altered by the addition of RF. Within the formulations, the composite with 15 wt.% RF had the best combination of properties: higher VST and HDT values responsible for more dimensional stability at high temperatures, lower CLTE producing lesser thermal expansion, comparatively better thermal conductivity and more heat dissipation. Eventually, there was a moderate
S, Thirumalvalavan, Senthilkumar, N., Selvarasu, S
Advancing Aerospace Interiors: Evaluation of the In-House Polymer Pellet Additive Manufacturing System2026-26-0765To be published on 06/01/2026
The Elektra printer is an open-source, pellet-based (FGF) 3 axis additive manufacturing system developed by Collins in collaboration with Pollen AM to enable large-scale, cost-efficient 3D printing using standard polymer pellets. In alignment with the Make in India program, Elektra represents a significant step toward localized, industrial-scale additive manufacturing that delivers affordability, flexibility, and performance for aerospace and allied industries. The system provides four major advantages. First, it enables cost-effective part production by leveraging standard injection molding grade thermoplastic pellets instead of expensive proprietary feedstocks. Second, its large build volume (800mm*800mm*400mm) supports the manufacture of tools, fixtures, and structural parts often restricted by conventional systems. Third, Elektra is compatible with a broad range of engineering and high-performance polymers that are flame retardant, ensuring adaptability for multiple use cases
Kini, Aditya Deepak, Sundar, Santosh
Wear Resilience Characteristics of 2% 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 used to strengthen the magnesium (AZ31) matrix by adding 2 wt.%. The composite is developed by disintegrated melt deposition vacuum stir casting method. Microstructural studies reveal the presence of Si3N4 particles and their uniform distribution. A L9 orthogonal array planned using Taguchi’s experimental design is chosen for three wear parameters axial load (AL), rotational speed (RS), and time duration (TD) for trials as per G99 standard in pin-on-disc apparatus. Experimental outcomes show a rise in axial stress; wear loss increases dramatically. Because the area of contact shrinks as sliding speed increases, wear loss diminishes dramatically. When the AL is low, CoF increases, and when the AL is large, CoF drops. When the sliding speed is increased, CoF decreases. To optimize multiple responses effectively, the TOPSIS method (Technique for Order of Preference by Similarity to Ideal Solution) was
Senthilkumar, N., Dhinakar Raj, C K
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. Barlat2000), 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
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 an effort to create polymer composites that are less harmful to the environment, the use of biodegradable polymers has been investigated in recent years. Injection molding was used to create a biodegradable polymer composite containing 20 wt.% vetiver fibers (VFs) and 2 wt.% nano-silica (nSiO2) obtained from pearl millet. Parts for unmanned aerial vehicles, interior cabin panels, seating structures, and secondary structural components were made of this composite. Desirability analysis was used to examine and optimize machining (drilling) studies that were designed according to Taguchi's design (L9 orthogonal array). Surface roughness (Ra) and delamination factor (DF) were taken as outputs, while spindle speed (SS) ranging from 1000 to 3000 rpm, feed rate (FR) from 15 to 45 mm/min, and drill diameter (DD) from 6 to 10 mm were used as inputs. The developed
Senthilkumar, N.
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 in aerospace manufacturing demands a fundamental shift from traditional end-of-pipe solutions to circular design principles embedded from the earliest stages of product development. This paper presents a practical framework for integrating circularity into aerospace systems, emphasizing design strategies that minimize material waste, facilitate disassembly, and enable component recovery throughout the product lifecycle. The approach is structured around five key pillars: 1. Design for Modularity and Disassembly 2. Material Substitution to Enhance Recyclability 3. Waste Segregation and Characterization in Manufacturing Processes 4. Component-Level Circularity Readiness Scoring 5. Collaborative Supplier Engagement to Establish End-of-Life Pathways To support implementation, a Circularity Readiness Assessment Tool has been developed, enabling engineers to evaluate designs against circularity criteria such as disassembly ease, material recyclability, and supplier
S, Chaitra
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)4/13/2026
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
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
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
Accurate Simulation of Sealing Process using a GPU-Accelerated Lagrangian Differencing Dynamics Method2026-01-04924/7/2026
The car body consists of many parts, between which there are cavities and gaps that water, dust, and noise can enter. To prevent corrosion and reduce noise, these gaps are sealed with a paste featuring complex non-Newtonian properties. Sealing also serves a cosmetic function for visible areas, which demands high quality for better customer satisfaction. Usually, bead length can reach several meters with a height of 0.5-5 mm and a width of 5-40 mm. In this situation, optimizing the robotic paths and sealant flow can speed up production and reduce costs. Accurate and fast CFD modeling helps with planning the sealing process, shortening vehicle development cycles and minimizing costs. Due to the complexity of vehicle body geometry, arbitrary robotic movements, sealing bead length, free surface, and the complex rheological material properties, traditional CFD simulations have difficulties in modelling this process. This paper presents a new framework for modelling the sealing processes
Panov, Dmitrii Olegovich, Zhu, Huaxiang, Basic, Josip, Zhang, Lingran, Kotian, Akhilesh, Menon, Muraleekrishnan, Borra, Ravi Kanth, Ando, Yuya
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
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
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
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
CFD Modeling of Gas Formation and Venting During the EV’s Battery Cells Manufacturing Process2026-01-03844/7/2026
The battery is a critical component of electric vehicles (EVs), where high power demands pose significant operational challenges. One such challenge is gas generation within the porous anode layer, which can lead to pressure buildup inside the battery. The complex interfacial dynamics at the microscale play a crucial role in determining the effectiveness of gas venting and the resulting pressure evolution. This study examines the effect of gas generation at two different length scales on the pressure rise and bubble dynamics. First, gas generation within a representative anode microstructure sample is investigated using a Volume of Fluid (VOF) framework that resolves tortuous flow passages. The simulations reveal that gas generation in such microstructures can lead to pressure rises of several thousand Pascals, with interfacial behavior primarily governed by surface tension effects. Second, a high-level single-cell simulation is performed using a porous media approach to evaluate
Mahyawansi, Pratik J., Schlautman, Jeff, Viswanath, Priyanka, Srinivasan, Chiranth
Sideslip Angle Estimation for Mining Trucks Based on Real-Time Cornering Stiffness Identification2026-01-06184/7/2026
High-precision estimation of key vehicle–road state parameters is crucial for ensuring the accurate and safe control of mining trucks (MT), as well as for reliable trajectory tracking. Among these parameters, the vehicle sideslip angle is particularly critical for assessing and predicting lateral stability. However, its direct measurement is challenging, and its estimation typically depends on an accurate characterization of tire cornering stiffness. For MT, large variations in loading conditions (from empty to fully loaded) pose significant challenges to sideslip angle estimation due to the resulting nonlinearity and variability of tire cornering stiffness. To address this issue, a novel joint estimation framework integrating the Moving Horizon Estimation (MHE) and Square-Root Cubature Kalman Filter (SCKF) is proposed to simultaneously achieve high-precision estimation of both tire cornering stiffness for each tire and vehicle sideslip angle. In this framework, the cornering stiffness
Xia, Xue, Shen, Peihong, Jiao, Leqi, Li, Tao, Chen, Huiyong, Zhao, Kun, Jiao, Leqi, Zhao, Zhiguo
Conjugate Heat Transfer Modeling for Predicting Thermal Behavior of X76 Emotor Windings2026-01-01184/7/2026
A computational study based on a conjugate heat transfer (CHT) method in SimericsMP+ was performed to predict the winding temperatures in an X76 emotor. In this study, the thermal load was represented in the simulation through the solution of electromagnetic equations in SimericsMP+, where heat generation was driven by root-mean-square (RMS) current, while liquid cooling was applied at flow rates ranging from 1 LPM to 6 LPM. Simulations were conducted to measure the temperature on three thermocouple locations on each side of the winding crown and weld regions under steady operation. The computational strategy employed a loosely coupled approach. A fluid-only simulation was first carried out to establish stable flow conditions, followed by coupling with solid conduction where the winding acted as the heat source. The predicted temperature distributions were then compared with test data. Results obtained show good agreement, with differences remaining within an acceptable range, thereby
Jia, Kun, Schlautman, Jeff, Srinivasan, Chiranth
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
NASA Tech Briefs: April 202626AERP044/2/2026
Leonardo DRS Expands Production Capacity to Advance Naval Power, Sensors, and AI-Driven Mission Systems Success at Sea: NIWC Atlantic Uncrewed Surface Vessel Completes Fastest Transatlantic Crossing High‑Speed Spindles Unlock Five‑Axis Machining Innovation with Smaller Tools Why CFD is Stuck in the File Era Accurate and Resilient GNSS Timing Modules for Critical Infrastructure Undetectable Ship-to-Ship Laser Communications EP40: Structural Epoxy Used for Steel Bonding in Marine Applications Master Bond EP40 is a two-part, room temperature curing epoxy for bonding, sealing, coating, and encapsulating. EP40 bonds well to a variety of substrates, including naval steel, the primary structural metal used in the shipbuilding industry Vortex Research to Solve Aviation's Efficiency Tradeoff with Active Strakes A research team developed a smart strake system that dynamically adapts to flight conditions, showing a promising drag reduction in the wind tunnel with respect to passive strakes. This
Advancing Steel Joining: A Critical Review of Adhesives and Sealants for High-Performance Automotive and Construction Applications05-19-04-00253/31/2026
For centuries, steel has been a cornerstone material for structural construction; by contrast, adhesive joining is a relatively nascent technology, particularly in heavy structural applications. The present article aims to provide the reader a review of the applications of adhesive joining in steel-based applications. Steel being a popular material in many industries due to its excellent mechanical properties, but traditional joining methods might have certain limitations viz. ability to withstand vibrations or movement, distortion, difficult to repair, and the like. Adhesive joining provides an alternative approach that offers advantages like reduced weight, improved corrosion resistance, enhanced aesthetics, ability to join multi-materials, ability to resist vibrations to a certain limit, and the like. This article examines the use of steel within the automotive and construction industries, intentionally narrowing its scope from steel’s broader range of applications. This article
S., Shrray, Arora, Kanwer Singh
Steel Bars, Forgings, Mechanical Tubing and Forging Stock, Nitriding, 1.4Cr - 1.2Mo - 0.3V (0.29 - 0.36C) (32CrMoNiV5), Aircraft-Quality for Bearing ApplicationsAMS6496C (Current)3/13/2026
This specification covers a nitriding grade of aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock. AMS6497 and AMS6498 cover UNS K23280 having other quality levels.
AMS E Carbon and Low Alloy Steels Committee
Alloy, Corrosion- and Heat-Resistant, Bars, Forgings, Rings and Stock for Forgings and Rings, 50Ni - 20Cr - 20Co - 5.8Mo - 2.2Ti - 0.45Al (Nimonic® Alloy 263), Consumable Electrode or Vacuum Induction Melted, 2100 °F (1149 °C) Solution Heat TreatedAMS5886E (Current)3/13/2026
This specification covers a corrosion- and heat-resistant nickel alloy in the form of bars, forgings, flash-welded rings, and stock for forging or flash-welded rings.
AMS F Corrosion and Heat Resistant Alloys Committee
Filler Metal, Aluminum Brazing, 12SiAMS4185G (Current)3/13/2026
This specification covers an aluminum alloy in the form of wire, sheet, foil, pig, grains, shot, and chips (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Die and Hand Forgings, and Rolled Rings, 2.3Cu - 1.6Mg - 1.1Fe - 1.0Ni - 0.18Si - 0.07Ti (2618-T61), Solution and Precipitation Heat TreatedAMS4132J (Current)3/13/2026
This specification covers an aluminum alloy in the form of die forgings, hand forgings, and rolled rings 4 inches (102 mm) and under in nominal thickness and forging stock of any size (see 8.6).
AMS D Nonferrous Alloys Committee
Quality Assurance Sampling and Testing, Corrosion- and Heat-Resistant Steel and Alloy ForgingsAMS2374G (Current)3/13/2026
This specification covers quality assurance sampling and testing procedures used to determine conformance to applicable material specifications of corrosion- and heat-resistant steel and alloy forgings.
AMS F Corrosion and Heat Resistant Alloys Committee
SAE TOMORROW TODAY - Meet The Historical Engineering Storytellers135583/9/2026
From lifelong hobbies to deep nostalgia, there is no doubt that personal connections with our vehicles are real. But true car lovers know that the future is built on what we've learned from the past. Listen in as we sit down with SAE History of Ground Vehicle Systems Committee, members Terry Mueller, George Nicols, and Jeff Singer to explore what makes cars so special. As historical engineering storytellers, these automotive enthusiasts are creating a library within SAE that includes the evolution of vehicle systems and subsystems, making knowledge accessible for enthusiasts, engineers, and educators alike. If you're an industry professional, retired engineer, or automotive enthusiast with experience in the automotive or aerospace sectors, learn how you can join and help us preserve history. 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 a moment to follow SAE Tomorrow Today--a podcast where we
Patterson, Lori
Modification of Composite Cathode for Sulfide-Based All-Solid-State Batteries2026-01-70372/27/2026
All-solid-state batteries (ASSBs) based on sulfide electrolytes hold great promise for next-generation energy storage, yet their performance is critically constrained by unstable cathode–electrolyte interfaces. Here, we report a dual-modification strategy utilizing ionic liquids (ILs) in combination with lithium salts to simultaneously improve interfacial wettability, ionic transport, and electrochemical stability in NCM811 composite cathodes. Three ILs (EMIMTFSI, Pyr₁₄FSI, and PP₁₃FSI) and three lithium salts (LiTFSI, LiDFOB, and LiBOB) were systematically evaluated and screened. While neat ILs improved initial capacities by reducing solid–solid contact resistance, they also triggered parasitic reactions with sulfides, resulting in capacity fading. Among the lithium salts, LiBOB was identified as the most chemically compatible additive, forming thin and uniform hybrid interphases enriched with B–O species. This interphase effectively suppressed high-voltage side reactions and reduced
Gu, Yu-Yang, Tian, Shi-Yu, Qi, Ji, Yang, Li-Peng, Zhan, Wen-Wei, Yang, Xiao-Guang, Yi, Yong
A Thin-Film Flexible Temperature-Strain Multimodal Sensor for Lithium-Ion Battery Monitoring Based of Laser Direct Writing2026-01-70262/27/2026
Multimodal sensors, capable of simultaneously acquiring multiple physical or chemical signals, have shown broad application potential in fields such as health monitoring, soft robotics, and energy systems. However, current multimodal sensors often suffer from complex fabrication processes and signal decoupling challenges, which limit their practical deployment. To address these issues, this work presents a thin-film temperature–strain multimodal sensor (FTSMS) fabricated via laser processing. The temperature-sensing unit, based on the Seebeck effect, achieves a sensitivity of 9.08 μV/°C, while the strain-sensing unit, utilizing BaTiO₃/AlN@PDMS as the sensitive layer, exhibits a gauge factor (GF) of 43.2. By integrating distinct sensing mechanisms (thermovoltage for temperature and capacitance change for strain), the FTSMS enables self-decoupled measurements over 20–90 °C. Applied in LIB monitoring, it successfully captures real-time temperature and strain variations during charge
Wang, Ziwei, Li, Zhenglin, Gao, Yang, Xuan, Fuzhen
Simulation-Based Evaluation of Lithium-Ion Batteries Manufacturing Performance2026-01-70052/27/2026
Lithium-ion batteries (LIBs) have become indispensable components in diverse energy applications driven by their high energy density, long cycle life, and low self-discharge. These excellent characteristics are directly influenced by their manufacturing processes, where variations in battery design and processing parameters will lead to significant differences in performance. Therefore, reliable and efficient evaluation of battery performance across manufacturing processes is essential for quality assurance and process improvement. Traditional methods rely on formation cycling and associated electrochemical tests, which are time and cost intensive. Different from them, a simulation-based approach for manufacturing performance evaluation is proposed in this study. The method employs the pseudo two dimensions (P2D) electrochemical model within the PyBaMM framework, where model parameters such as electrode type, electrode size, and particle size are derived from manufacturing data and
Yan, Yifei, Meng, Jinhao, Song, Zhengxiang, Zhang, Shirui, Pan, Yuhao, Yang, Peihao, Peng, Jichang
Aerospace Standards Index - 2026ASIN20262/25/2026
This valuable resource lists all Aerospace Standards (AS), Aerospace Recommended Practices (ARP), Aerospace Information Reports (AIR), and Aerospace Resource Documents (ARD) published by SAE. Each listing includes title, subject, document number, key words, new and revised documents, and DODISS-adopted documents. AMS Index - Now Available!
On the Modal Characteristics of Motor Stators under Different Interlaminate Fastening Conditions14-15-01-00052/14/2026
The increasing demand for quiet and efficient electric vehicles has highlighted the importance of understanding vibration and noise characteristics of motor stators. Previous studies have extensively modeled electromagnetic excitation and laminated structures, but there has been little experimental evidence clarifying how different interlaminate fastening methods affect vibration modes under comparable conditions. This knowledge gap limits the ability to optimize fastening strategies for noise and vibration control in practical motor design. In this study, laminated stator cores were fabricated with different fastening conditions—bolting, clinching, and welding—and subjected to vibration testing and experimental modal analysis. Natural frequencies, damping ratios, and mode shapes were identified for torsional, circumferential, and breathing modes. The results revealed that the in-plane torsional natural frequencies increase with bolt axial force, while clinching provides additional
Matsubara, Masami, Saito, Akira, Shimada, Shogo, Oishi, Taizan, Furuya, Kohei, Kawamura, Shozo, Tajiri, Daiki
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