Browse Topic: Forming

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Comparison of Different Joining Techniques as a Benchmark for Integrally Joined Thermoformed Components Based on Tailored rCF Organosheets2025-01-0170To be published on 04/25/2025
Climate-neutral aviation requires resource-efficient composite manufacturing technologies and viable solutions for the reuse of carbon fibers (CF). In this context, thermoplastic composites (TPC) can make a strong contribution. Thermoforming of TPC is an efficient and established process for aerospace components. But it’s efficiency could be further increased by integration of joining processes, which would otherwise be separate steps. In this work, a two-step thermoforming process for hollow box structures, particularly uplift structures, is presented. The starting point are two organosheets. First, one of the organosheets, intended for the bottom skin of the uplift structure, is thermoformed. After cooling, the press opens, the organosheet remains in the press and an infrared heater is pivoted in, to locally heat up just the joining area. Meanwhile, a second organosheet, intended for the top skin, is heated and thermoformed and simultaneously joined to the lower skin, thereby forming
Vocke, Richard, Seeßelberg, Lorenz, Focke, Oliver, Dietrich, Jan Yorrick, Jobke, Katrin, Albe, Christopher, May, David
Technical Paper
Predicting Forming Limit of Hot Stamping Boron Steel using a Modified Zener-Hollomon Parameter based Ductile Failure Criterion2025-01-8225To be published on 04/01/2025
This study combines a recently proposed ductile failure criterion with a modified Zener-Hollomon parameter to predict the forming limit of a boron steel at hot stamping temperatures. The Zener-Hollomon parameter is modified to include a parameter that accounts for the non-linear variation of strain rate during hot stamping. The combined ductile failure criterion takes into account the critical damage at localized necking or at fracture as a function of strain path, initial sheet thickness and strain rate variation. The process of determining various parameters in the failure criterion is explained. The capability of the ductile failure criterion is demonstrated by predicting forming limit of a boron steel in an isothermal Nakajima dome test. The criterion is further demonstrated by predicting fracture in hot stamping a B-Pillar part (NUMISHEET Benchmark #3 2008).
Sheng, ZiQiang, Mallick, Pankaj
Technical Paper
Understanding Forming Characteristics of 980 MPa and 1180 MPa strength level AHSS with various Microstructures2025-01-8222To be published on 04/01/2025
For electrical vehicle (EV) automotive body-in-white (BIW) structures, protection of passengers and battery in crash event becomes critically important. In addition to energy absorption, intrusion protection for battery and vehicle becomes extremely important and Advanced high strength steels (AHSS), like dual phase (DP)/multi-phase (MP)/complex phase (CP)/retained austenite bearing (GEN3) steels and Press hardened steels (PHS), have become material of choice for design for these components. Higher yield strength materials especially in 980/1180MPa MP and CP category are chosen for part design over conventional low yield strength DP to meet crash and performance targets. In this study, the forming characteristics including both global and local formability are evaluated and compared among 980 DP/MP/CP grades. Formability tests, such as forming limit curve (FLC), true fraction strain, V bend, half dome, and hole expansion tests are conducted. Microstructure analysis to understand the
Shih, Hua-Chu, Pednekar, Vasant, Shi, Ming, Singh, Jatinder, Tedesco, Sarah, Wu, Wei
Technical Paper
Zero circumferential material flow line-based method for reducing stamping simulation cost2025-01-8224To be published on 04/01/2025
In sheet metal simulation, computation time is significantly influenced by the number of elements used to discretize the sheet blank, which covers the shape of forming tool geometry. Based on particle kinematics, motion of material point is modeled, and the concept of zero circumferential motion material line (ZML) is proposed. The slope ratio of material line (SRML) is proposed to quantify the circumferential deviation for determining the ZML. Based on the SRML, a method is developed to segment sheet blank and apply constraints. The method is demonstrated through forming simulation on a Hishida geometry. The proposed method, with its minimal to no circumferential motion along ZMLs, exhibits high level of accuracy retention while simultaneously impressively reducing computation time (up to 77%). This combination of efficiency and precision makes it a compelling approach for reducing simulation cost.
Sheng, ZiQiang, Asimba, Brian, Cabral, Kleber
Technical Paper
Finite Element Simulation and Experimental Study of the In-Mold Graining Process2025-01-8330To be published on 04/01/2025
In-Mold Graining (IMG) is an innovative production technology applied to the skin wrapping of automotive interior components. In the design of automotive interior components of door panels and instrument clusters, to overcome process-related problems, such as the thinning of grain patterns and excessive reduction in thickness, simulation of the skin vacuum forming process is required. The Thermoplastic Olefin (TPO) skin material is investigated in this paper, and a viscoelastic mechanical model for this material is established. Dynamic Mechanical Analyzer (DMA) is utilized to perform scan for frequency and temperature, and the tested data is used to obtain key model parameters of the viscoelastic constitutive model. Based on the experimental data, the study explores how to calculate the relaxation time spectrum to describe the viscoelastic properties of TPO material during the vacuum adsorption process. Numerical simulation of the vacuum adsorption process of TPO material is conducted
Chai, Bingji, Guo, Yiming, Xie, Xinxing, Zhang, Qu
Technical Paper
NdFeB Magnets Manufactured by Hot Pressing Using Strip-Cast and Melt-Spun Powders2025-01-8217To be published on 04/01/2025
The initial powder used for the manufacturing of NdFeB permanent magnets is usually prepared either by melt spinning or strip casting. The powders produced by these two methods show different particle shapes and sizes which may be suitable for different applications, e.g., manufacturing bonded, sintered, or hot-deformed magnets. While melt-spun powder is a good initial material for bonded and hot-deformed magnets, strip-cast powder is normally used for sintered magnets. In this study, NdFeB powders manufactured by melt spinning and strip casting were hot pressed (without particle alignment) under the same conditions. Although the processing parameters are exactly the same (pressed in the same mold), the magnetic properties of the magnets made from the two powders are significantly different. The magnet made from the strip-cast powder (after ball milling) shows reasonably good magnetic properties, with a coercivity (HcJ) of 1270 kA/m and a remanence (Br) of 0.7 T, while that made from
He, Youliang, Song, Shaochang, Walsh, Dan, Bernier, Fabrice, Mozharivskyj, Yurij, Peng, Philip
Technical Paper
A review of warm forming for steels: History, Methodology and Emerging trends2025-01-8814To be published on 04/01/2025
Many manufacturing techniques and process modifications have been implemented over the years to improve the formability of sheet metals. Warm forming of sheet metals is one such established method. However, it is more commonly and successfully applied to aluminum grades. The reevaluation of less-used metal forming technologies, such as warm forming and sheet hydroforming for steel, is a response to the challenges posed by competitive processes like large castings and the geometry requirements of new BEV parts. By understanding the effects of elevated temperatures (below recrystallization temperatures) on different steel grades and the impact of various heating methodologies, the industry can adapt and optimize these proven techniques for modern applications. This paper is a comprehensive summary of the effect of elevated temperatures on various grades of steel. Different heating techniques, their cycle times and effects on final forming feasibility is contrasted. The effect of
Kella, Caroline, Wormald, Tom
Technical Paper
A Methodology to Characterize the Influence of Paint Baking and Pre-Straining on the Tensile Properties and Sheared Edge Sensitivity of Third Generation Advanced High Strength Steels2025-01-8223To be published on 04/01/2025
The existing ASTM A653 standard for characterization of the bake hardening index (BHI) involves application of a pre-strain followed by bake hardening and subsequent testing of an ASTM-E8 tensile coupon that can lead to premature fracture in steels with high strengths and lower elongations. To this end, a new test procedure is proposed with application to 980 and 1180 MPa third generation advanced high strength steels (3G-AHSS). The proposed methodology involves pre-straining over-sized tensile specimens using the so-called KS-1B geometry, which is followed by the extraction of an ASTM E8 sample from the gauge region on which the baking and secondary tensile testing are conducted. Various pre-strain levels from 2% to 10% were considered with all tests performed using the proposed methodology avoiding premature fracture compared to the ASTM A653 method that was evaluated for pre-strain levels of 2% and 8%. Finally, to characterize the influence of paint baking on regions with
Northcote, Rhys, Berry, Avalon, Narayanan, Advaith, Tolton, Cameron, Lee, Haea, Smith, Jonathan, McCarty, Eric, Butcher, Cliff
Technical Paper
Deformation Behavior and Springback Analysis of Anti-Collision Beam on Bending Forming2025-01-8247To be published on 04/01/2025
Since aluminum alloys (AA) are widely used as structural components across various industries, higher requirements for shape-design, load-bearing, and energy-absorption capacity have been put forward. In this paper, we present the development of a numerical model, integrated with a compensation method, that effectively predicts processing defects in the anti-collision beam of a vehicle, resulting in a marked improvement in its forming quality. Specifically, different constitutive models are investigated for their applicability to the beam, enabling a precise evaluation of its structural performance under large deformation. The Johnson-Cook failure model is introduced to better characterize the fracture behavior of the beam under severe structural damage. The three-point bending experiment served as a rigorous examination, demonstrating good consistency between the experimental and simulation results. Furthermore, a prediction model for assessing the forming quality during the bending
Zhang, Shizhen, Meng, Dejian, Gao, Yunkai
Technical Paper
Aluminum Alloy Extrusions, 4.4Cu - 1.5Mg - 0.60Mn (2024-T3), Solution Heat Treated and Cold WorkedAMS4152P (Current)03/05/2025
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, shapes, and tubing produced with cross-sectional area of 32 square inches (206 cm2), maximum (see 8.6).
AMS D Nonferrous Alloys Committee
Material Specification
Aluminum Alloy, Extrusion, 2.7Cu - 1.8Li - 0.7Zn - 0.3Mn - 0.3Mg - 0.08Zr (2099-T83), Solution Heat Treated, Stress Relieved by Stretching 1 to 4% and AgedAMS4287C (Current)02/25/2025
This specification covers an aluminum alloy in the form of extruded bars, rods, and profiles (shapes) produced with nominal thickness up to 3.000 inches (76.20 mm), inclusive, and having a cross-sectional area of 42 square inches (271 cm2) maximum and a circumscribing circle diameter (circle size) of 15 inches (38 cm) maximum (see 2.4.1 and 8.8).
AMS D Nonferrous Alloys Committee
Material Specification
Evaluating Cone and Pyramid Frustums with Constant and Varying Wall Angles in Single-Point Incremental Sheet Forming05-18-03-001902/07/2025
Incremental sheet forming is a dieless forming process. Innovative analysis of deformations in the SPIF process, utilizing four distinct sets of deformed structures. Each set consists of four deformed shapes that are categorized as constant and variable tool path, as well as process characteristics including deformed shape, spindle speed, step size, and feed rate. The objective of this article is to investigate the variation of forming force, surface roughness, hardness value, strain rate, forming limit curve (FLC), and strain against forming depth and is to optimize its process parameters. Pyramid frustums have a lower surface roughness than conical frustums. Deformation depth affects hardness at different points along the frustum. The hardness value of the pyramid frustum is often higher than that of the conical frustum. As no single parameter is demonstrated to be significant in determining strain rate, the deformed shape is more relevant than the other process parameters. This
Bhasker, Radhe Shyam, Kumar, Yogesh, Kumar, Santosh, Singh, Rajnish
Journal Article
Utilizing High-Performance Thermoplastics to Improve Durability and Efficiency in Automotive Instrument Panels2024-01-524501/28/2025
The present research explores the potential of high-performance thermoplastics, Polymethyl Methacrylate and Polyurethane, to enhance the passive safety of automotive instrument panels. The purpose is to evaluate and compare the passive safety of these two materials through the conduct of the Charpy Impact Test, Tensile Strength Test, and Crush Test —. For this, five samples were prepared in the case of each material via injection moulding, which enabled reliability, and consistency of the findings. As a result, it was found that in the case of the Charpy Impact Test, the average impact resistance varies with PMMA exhibiting a level of 15.08 kJ/m2 as opposed to the value of 12.16 kJ/m2 for PU. The Tensile Strength Test produced the average tensile strength of 50.16 for PMMA and 48.2 for PU, which implied superior structural integrity under tension for the first type of thermoplastic. Finally, the Crush Test showed that PMMA is more resistant to crushes on average than PU with the
Natrayan, L., Kaliappan, Seeniappan, Mothilal, T., Balaji, N., Maranan, Ramya, Ravi, D.
Technical Paper
Aluminum Alloy, Extrusions, 4.4Cu - 1.5Mg - 0.60Mn (2024-T81), Solution Heat Treated, Cold Worked, and Precipitation Heat TreatedAMS4491A (Current)01/22/2025
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing produced with cross-sectional area of 32 square inches (206 cm2), maximum (see 8.6).
AMS D Nonferrous Alloys Committee
Material Specification
Nickel-Iron Alloy, Magnetic, Sheet and Strip 50Ni - 50Fe Stamping Quality, Half-Hard TemperAMS7719F (Current)01/22/2025
This specification covers a magnetic nickel-iron alloy in the form of sheet and strip.
AMS E Carbon and Low Alloy Steels Committee
Material Specification
Aluminum Alloy, Extrusions, 4.4Cu - 1.5Mg - 0.60Mn (2024-T8511), Solution Heat Treated, Cold Worked, Stress-Relieved by Stretching, Precipitation Heat Treated, and StraightenedAMS4423A (Current)01/22/2025
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing produced with cross-sectional area of 32 square inches (206 cm2) maximum (see 8.6).
AMS D Nonferrous Alloys Committee
Material Specification
Nickel-Iron Alloy, Magnetic, Sheet and Strip 50Ni - 50Fe Annealed, Forming GradeAMS7717F (Current)01/22/2025
This specification covers a magnetically soft nickel-iron alloy in the form of sheet and strip.
AMS E Carbon and Low Alloy Steels Committee
Material Specification
Aluminum Alloy, Extrusion, 3.7Cu - 1.15Li - 0.5Zn - 0.45Ag - 0.4Mg - 0.3Mn - 0.1Zr (2055-T84), Solution Heat Treated, Stress Relieved by Stretching 2% to 5% and AgedAMS4257A (Current)01/22/2025
This specification covers an aluminum alloy in the form of extruded bars, rods, and profiles.
AMS D Nonferrous Alloys Committee
Material Specification
Superfinishing of HVOF Applied Tungsten Carbide CoatingsAMS2452 (Current)01/09/2025
This specification covers requirements for the superfinishing of High Velocity Oxygen/Fuel (HVOF) applied tungsten carbide thermal spray coatings.
AMS B Finishes Processes and Fluids Committee
Material Specification
Aluminum Alloy, Extrusions, 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr (7075-T73, 7075-T73511, 7075-T73510), Solution Heat Treated, Stress Relieved by Stretching when required, and OveragedAMS4617B (Current)12/10/2024
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, shapes, and tubing 0.040 to 4.499 inches (1.01 to 114.27 mm), inclusive, in nominal diameter or least thickness and with areas up to 32 square inches (206 cm2), inclusive (see 8.6).
AMS D Nonferrous Alloys Committee
Material Specification
Effect of Nano Silica on the Mechanical Behaviour of High Impact Polypropylene/Nano Clay Composites2024-01-521112/10/2024
This study investigated the effect of nano silica on the mechanical behaviour of blends containing high impact polypropylene (hiPP) and nano clay. This study used nano silica from rice husk ash with an average particle size of 26 nm. The hiPP composites were mixed with 3 wt. % nano clay and different weight percentages (1%, 2%, and 3%) of nano silica were also added. The blending process used twin-screw extrusion, and composite samples were subsequently produced by injection moulding. Various parameters including tensile, compressive, and impact strengths were analyzed. In particular, the hiPP composite containing 3 wt. % nano clay and 2 wt. % nano silica had significantly improved mechanical properties, showing a 37.5% increase in tensile strength, a 56.8% increase in flexural strength, and a 51.4% increase in impact strength. It exhibited the highest tensile (53.51 MPa), flexural (67.19 MPa), and impact strength (5.17 KJ/m2) among all tested composites, demonstrating superior
Thangavel, Anand, Ragupathy, K., Manivannan, S., Murali, M.
Technical Paper
Efficient Robot Roller Hemming Process Using Turntable over Linear Setup2024-28-016412/05/2024
Hemming is an incremental joining technique used in the automotive industry, it involves bending the flange of an outer panel over an inner panel to join two sheet metal panels. Different hemming methods are available such as Press die hemming, Table-top hemming and Robot roller hemming. Robot roller hemming is superior to press hemming and tabletop hemming because of its ability to hem complex-shaped parts and is typically used in low-volume automotive production lines. For higher production volumes, such as 120 Jobs per Hour (JPH), press hem or tabletop hem is generally preferred. However, to achieve high-volume production from roller hemming method multi station setup is used. This static multi station setup can be configured into a Turntable setup. This new method eliminates the robot load and unload time at each station in the existing setup, resulting in a 40% increase in hemming robot utilization. Therefore, this process reduces the number of robots and the required floor space
Raju, Gokul, Roy, Amlan, Sahu, Shishir, Palavelathan, Gowtham Raj, Jagadeesh, Nagireddi, Chava, Seshadri
Technical Paper
Microstructural Characterization of Aluminium Alloys Used in Automotive Body Parts2024-28-015712/05/2024
To meet light-weighting and safety target of automotive vehicles, different Aluminium alloys are used in various body parts. Apart from conventional manufacturing process of gravity die casting (GDC), advanced manufacturing process such as low pressure die casting (LPDC), high pressure die casting (HPDC) and extrusion processes are also used to form complex automotive body parts. Steel parts are majorly used in automotive applications across world. However, steel has limitations with respect to light-weighting. To achieve light-weighting, now a days, there is trend to use these complex Aluminium parts in automotive industry to replace steel and integrate multiple parts into a single one. Aluminium has emerged as great potential for light-weighting and reducing complexity of handling multiple parts at an automotive plant. There is a challenge to identify suitable etchant for microstructural characterization of Aluminium alloy parts that can be made through various manufacturing
Deshmukh, Mansi, Jain, Vikas, Misal, Swapnali, Paliwal, Lokesh
Technical Paper
Optimizing the Capacity of Dozer Blade with Hydraulic Foldable Wings to Enhance Productivity2024-28-026812/05/2024
Crawler Dozers play a critical role in global construction, mining and industrial sectors, performing essential tasks like pushing the material, grading, leveling and scraping. In the highly competitive dozer market, meeting the growing demand for increased productivity requires strategies to enhance blade capacity and width. Dozer operations involve pushing the material and dozing, where blade capacity significantly influences performance. Factors such as mold board profile, blade height, and width impact the blade capacity which are crucial for productivity in light weight applications such as snow removal and dirt pushing. Blade width is also pivotal for grading and leveling tasks. Traditional blade designs, like straight or fixed U-type blades, constrain operator flexibility, limiting overall productivity. The integration of hydraulic-operated foldable wings on both sides of the blade offers the adaptability to adjust blade capacity which also helps to reduce material spillage
Sahoo, Jyoti Prakash, Sarma, Neelam Kumar
Technical Paper
Correlation Study for Radial Lash in Sliding Bushings of a Steering System2024-28-024912/05/2024
Investigation of clunking noise in a steering system fitted into a test vehicle indicated radial lash in sliding bushings, which are press fitted into housings, as one of the possible causes for clunk. To study the behavior of sliding bush under the influence of assembly clamp loads, manufacturing tolerances and road loads, sliding bushings are modelled in more detail in the steering system finite element models. Further for correlating the bushing measurements from test vehicle to the finite element model, a radial lash output is derived which is not directly available in finite element software. Finally, the correlated model is used to assess the updated design and check for radial lash improvement.
Badduri, Jaideep, Pandey, Ashish
Technical Paper
Aluminum Alloy, Extrusions, 4.4Cu - 1.5Mg - 0.60Mn (2024-T8510), Solution Heat Treated, Cold Worked, Stress-Relieved by Stretching, and Precipitation Heat Treated, UnstraightenedAMS4481A (Current)12/04/2024
AMS D Nonferrous Alloys Committee
Material Specification
Magnesium Alloy, Extrusions, 4.0Y - 2.25Nd - 0.5Zr (WE43C - T5), Precipitation Heat TreatedAMS4485B (Current)12/04/2024
AMS D Nonferrous Alloys Committee
Material Specification
Aluminum Alloy, Extrusions, 4.4Cu - 1.5Mg - 0.60Mn (2024-O), AnnealedAMS4421A (Current)12/04/2024
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing produced with cross-sectional area of 32 square inches (206 cm2), maximum (see 8.5).
AMS D Nonferrous Alloys Committee
Material Specification
EDITORIAL: Bauma the big one in 202524TOFHP12_0412/01/2024
December is a good time to reflect on the past year - to celebrate successes and consider opportunities for improvement - but it is also an opportune time to look to the future. As I think about the year ahead and appraise the tradeshow landscape that'll provide significant content for this magazine, mobilityengineeringtech.com, our e-newsletters and other multimedia products, none is bigger than Bauma in Munich, Germany, particularly in terms of the global construction and mining vehicle industries. The triennial event will cover an area that's equivalent to 86 soccer fields, according to Stefan Rummel, CEO of Messe München GmbH. Speaking to the press during an October virtual preview of Bauma 2025, which takes place from April 7-13, Rummel said that the number of exhibitors - expected to be about 3,600 - will be closer to the 2019 event versus the post-COVID-19 edition that was pushed back from its usual spring timeslot to the fall of 2022.
Gehm, Ryan
Magazine Article
Maximizing the Potential of TPU Extrusion in Medical Tubing ApplicationsTBMG-5216412/01/2024
Whether for vascular catheters or implantable devices, medical tubing must meet tough standards for flexibility, strength, and biocompatibility. That’s why more manufacturers are turning to thermoplastic polyurethanes (TPUs) that strike the ideal balance between these key properties, making them an excellent choice for high-performance medical tubing. Unlocking the best that TPUs have to offer means optimizing the extrusion process. This article looks at why TPUs are a top pick, the common obstacles in extrusion, and the ways manufacturers can fine-tune their process to get the most out of different grades.
Magazine Article
Development of a Robot-Assisted Fused Deposition Modeling Process for Enhanced Additive Manufacturing05-18-02-001111/09/2024
This work aims to define a novel integration of 6 DOF robots with an extrusion-based 3D printing framework that strengthens the possibility of implementing control and simulation of the system in multiple degrees of freedom. Polylactic acid (PLA) is used as an extrusion material for testing, which is a thermoplastic that is biodegradable and is derived from natural lactic acid found in corn, maize, and the like. To execute the proposed framework a virtual working station for the robot was created in RoboDK. RoboDK interprets G-code from the slicing (Slic3r) software. Further analysis and experiments were performed by FANUC 2000ia 165F Industrial Robot. Different tests were performed to check the dimensional accuracy of the parts (rectangle and cylindrical). When the robot operated at 20% of its maximum speed, a bulginess was observed in the cylindrical part, causing the radius to increase from 1 cm to 1.27 cm and resulting in a thickness variation of 0.27 cm at the bulginess location
Srivastava, Kriti, Kumar, Yogesh
Journal Article
Aluminum Alloy, Discontinuously Reinforced Extruded Bar, Rod, Wire and Shapes, (2124A/SiC/25p (0.7 µm) (T1P)AMS4369A (Current)10/28/2024
This specification covers a discontinuously reinforced aluminum alloy (DRA) made by mechanical alloying 2124A aluminum powder and silicon carbide particulate (SiC). It is produced in the form of extruded bar, rod, wire, and shapes with cross section inclusive of 1-inch (25.4-mm) diameter or less (see 8.7).
AMS D Nonferrous Alloys Committee
Material Specification
Aluminum Alloy, Discontinuously Reinforced Extruded Bar, Rod, Wire and Shapes, 2124A/SiC/25p (3 µm) - T1PAMS4379A (Current)10/11/2024
This specification covers a discontinuously reinforced aluminum alloy (DRA) made by mechanical alloying 2124A aluminum powder and silicon carbide (SiC) particulate. It is produced in the form of extruded bar, rod, wire, and shapes with cross section inclusive of 1-inch (25.4-mm) diameter or less (see 8.7).
AMS D Nonferrous Alloys Committee
Material Specification
Aluminum Alloy, Extrusions 4.0Cu - 1.3Mg - 0.60Mn (2026-T3511) Solution Heat Treated and Stress Relieved by StretchingAMS4338C (Current)10/08/2024
This specification covers an aluminum alloy in the form of extruded bars, rods, and profiles (shapes) with a maximum cross-sectional area of 25 square inches (161 cm2), a maximum circle size of 12 inches (305 mm), and a nominal thickness up to 3.250 inches (82.54 mm), inclusive (see 8.6).
AMS D Nonferrous Alloys Committee
Material Specification
Synthesis and Characterization of AA6351/SiC Composites Using Ball Milling Combined with Hot Extrusion05-18-01-000310/03/2024
In this investigation, AA6351 alloy matrix composites with a larger volume proportion of SiC (20 wt%) were fabricated and tested for microstructure and mechanical behavior. Composites were hot extruded from mechanically milled matrix and reinforcements. Hot extrusion uniformly distributed reinforcements in the matrix and strengthened phase interaction. Mechanical ball milling causes AA6351 powder to become more homogeneous, reducing the mean particle size from 38.66 ± 2.31 μm to 23.57 ± 2.31 μm due to particle deformation. The micrograph shows that the SiC particles are equally dispersed in the AA6351 matrix, avoiding densification and reinforcing phase integration issues during hot extrusion. In hot extrusion, SiC particles are evenly distributed in the matrix, free of pores, and have strong metallurgical bonds, resulting in a homogenous composite microstructure. SiC powders and mechanical milling increase microhardness and compressive strength, giving MMC-A 54.9% greater than AA6351
Saiyathibrahim, A., Murali Krishnan, R., Jatti, Vinaykumar S., Jatti, Ashwini V., Jatti, Savita V., Praveenkumar, V., Balaji, K.
Journal Article
Bemis, BASF develop lightweight hydraulic tank for compact excavators24TOFHP10_0610/01/2024
Bemis Manufacturing and BASF collaborated to develop a lighter-weight and lower-cost hydraulic tank for compact excavators that was recognized with a lightweighting award traditionally reserved for automotive innovations. Receiving an honorable mention in the Enabling Technology category of this year's Altair Enlighten Awards, the development team leveraged a combination of injection molding and vibration welding techniques to lower costs by approximately 20% and reduce mass by about 5% compared to the traditional roto-molding process. The solution also is more eco-efficient, delivering both environmental savings (reductions in lifecycle CO2 emissions) and reducing lifecycle costs.
Gehm, Ryan
Magazine Article
Steel, Extra High Toughness, Corrosion-Resistant, Bars, Wire, Forgings, Rings, and Extrusions 13Cr - 8.0Ni - 2.2Mo - 1.1Al Vacuum Induction Plus Consumable Electrode Melted, Solution Heat Treated, Precipitation Hardened (H1050)AMS5934/H1050 (Current)10/01/2024
This specification covers a corrosion-resistant steel product in the solution and precipitation heat-treated (H1050) condition, 12 inches (305 mm) and under in nominal diameter, thickness, or, for hexagons, least distance between parallel sides.
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Aluminum Alloy, Extrusions, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061-T4511 or T4510), Solution Heat Treated and Stress Relieved by StretchingAMS4172H (Current)09/10/2024
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing (see 8.6).
AMS D Nonferrous Alloys Committee
Material Specification
Aluminum Alloy Extrusions 2.7Cu - 2.2Li - 0.12Zr (2090-T86) Solution Heat Treated, Cold Worked, and Precipitation Heat TreatedAMS4232E (Current)09/09/2024
This specification covers an aluminum alloy in the form of extruded bars, rods, and profiles up to 0.499 inches (12.67 mm) in nominal diameter, or least thickness, and under 10 in2 (65 cm2) in cross-sectional area.
AMS D Nonferrous Alloys Committee
Material Specification
Steel, Extra High Toughness, Corrosion-Resistant, Bars, Wire, Forgings, Rings, and Extrusions 13Cr - 8.0Ni - 2.2Mo - 1.1Al Vacuum Induction Plus Consumable Electrode Melted, Solution Heat Treated, Precipitation Hardened (H1025)AMS5934/H1025 (Current)08/27/2024
This specification covers a corrosion-resistant steel product in the solution and precipitation heat-treated (H1025) condition, 12 inches (305 mm) and under in nominal diameter, thickness, or, for hexagons, least distance between parallel sides.
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Steel, Extra High Toughness, Corrosion-Resistant, Bars, Wire, Forgings, Rings, and Extrusions, 13Cr - 8.0Ni - 2.2Mo - 1.1Al Vacuum Induction Plus Consumable Electrode Melted, Solution Heat Treated, Precipitation Hardened (H950)AMS5934/H950 (Current)08/27/2024
This specification covers a corrosion-resistant steel product in the solution and precipitation heat-treated (H950) condition, 12 inches (305 mm) and under in nominal diameter, thickness, or, for hexagons, least distance between parallel sides.
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Steel, Extra High Toughness, Corrosion-Resistant, Bars, Wire, Forgings, Rings, and Extrusions 13Cr - 8.0Ni - 2.2Mo - 1.1Al Vacuum Induction Plus Consumable Electrode Melted Solution Heat Treated, Precipitation Hardened (H1150)AMS5934/H1150 (Current)08/27/2024
This specification covers a corrosion-resistant steel product in the solution and precipitation heat-treated (H1150) condition, 12 inches (305 mm) and under in nominal diameter, thickness, or, for hexagons, least distance between parallel sides.
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Steel, Extra High Toughness, Corrosion-Resistant, Bars, Wire, Forgings, Rings, and Extrusions 13Cr - 8.0Ni - 2.2Mo - 1.1Al Vacuum Induction Plus Consumable Electrode Melted, Solution Heat Treated, Precipitation Hardened (H1100)AMS5934/H1100 (Current)08/27/2024
This specification covers a corrosion-resistant steel product in the solution and precipitation heat-treated (H1100) condition, 12 inches (305 mm) and under in nominal diameter, thickness, or, for hexagons, least distance between parallel sides. The aged product may be supplied directly by a producer or by another entity performing the functions of a producer as defined in AS6279. The latter can be accomplished by precipitation heat treatment of solution treated material previously certified to AMS5934. The entity assuming responsibility for the aging operation is designated the producer of AMS5934/H1100.
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Steel, Extra High Toughness, Corrosion-Resistant, Bars, Wire, Forgings, Rings, and Extrusions 13Cr - 8.0Ni - 2.2Mo - 1.1Al Vacuum Induction Plus Consumable Electrode Melted Solution Heat Treated, Precipitation Hardened (H1000)AMS5934/H1000A (Current)08/19/2024
This specification covers a corrosion-resistant steel product in the solution and precipitation heat treated (H1000) condition, 12 inches (305 mm) and under in nominal diameter, thickness, or, for hexagons, least distance between parallel sides.
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
CRIMPING TOOLS, TERMINAL, HAND, WIRE TERMINATION; IN-SERVICE INSPECTION GAGES FOR TYPE II AS22520/5, /10, AND MIL-T-22520/32 (CANCEL) CRIMP TOOLSAS22520/6B (Current)08/09/2024
AE-8C2 Terminating Devices and Tooling Committee
Technical Standard
Aluminum Alloy Extrusions, 7.9Zn - 1.6Cu - 2.2Mg - 0.16Cr (7249-T76511), Solution Heat Treated, Stress-Relieved, Straightened, and OveragedAMS4293B (Current)07/25/2024
This specification covers an aluminum alloy procured in the form of extruded bars, rods, wire, profiles (shapes), and tubing up to 1.499 inches (38.07 mm), inclusive, in nominal diameter or least thickness (bars, rods, wire, or profiles) or nominal wall thickness (tubing) (see 8.6).
AMS D Nonferrous Alloys Committee
Material Specification
Steel and Aluminum Molds: The Effect of Thickness on Productivity and Part Quality05-17-04-002406/28/2024
The use of aluminum to manufacture injection molds aims to maximize the productivity of plastic parts, as its alloys present higher heat conductivity than tool steel alloys. However, it is essential to accurately control the injection molding parameters to assure that the design tolerances are achieved in the final molded plastic part. The purpose of this research is to evaluate the use of aluminum alloys in high-volume production processes. It delves into the correlation between the type of material used for mold production (steel or aluminum) and the thickness of the injected part, and how these variables affect the efficiency of the process in terms of the quantity and quality of the produced parts. The findings suggest that replacing steel molds with aluminum alloys significantly reduces injection molding cycle time, the difference ranging from 57.1% to 72.5%. Additionally, the dimensional accuracy and less distortion provided by aluminum have improved product quality. In case of
Marconi, Pedro, Amarante, Evandro, Ferreira, Cristiano, Beal, Valter, Ribeiro Júnior, Armando
Journal Article
Prediction of Tribological Behavior of Acrylonitrile Butadiene Styrene Polymer Matrix Composites Employing Copper Powders05-17-04-002606/27/2024
This research examines the impact of different amounts of copper (Cu) powder on the wear characteristics of acrylonitrile butadiene styrene (ABS)–Cu composites. Various formulations of ABS–Cu composites have been produced using injection molding, with different amounts of surfactant. Wear properties were evaluated by conducting tribological testing in accordance with ASTM standards. The findings indicated a decrease in wear loss, particularly when using a mixture consisting of 23% ABS, 70% Cu, and 7% surfactant. Machine learning regression algorithms successfully forecasted wear behavior with R-squared values over 0.97. The models used in the analysis included linear, stepwise linear, tree, support vector machine (SVM), efficient linear, Gaussian progression, ensemble, and neural network regression models. This research emphasizes the significance of composite materials in fulfilling contemporary technical requirements. The acquired insights enable the development of materials with
Jatti, Vijaykumar S., Saiyathibrahim, A., Murali Krishnan, R., Balaji, K.
Journal Article
Model-Based Algorithm for Water Management Diagnosis and Control of PEMFC Systems for Motive Applications2024-37-000406/12/2024
Water management in PEMFC power generation systems is a key point to guarantee optimal performances and durability. It is known that a poor water management has a direct impact on PEMFC voltage, both in drying and flooding conditions: furthermore, water management entails phenomena from micro-scale, i.e., formation and water transport within membrane, to meso-scale, i.e., water capillary transport inside the GDL, up to the macro-scale, i.e., water droplet formation and removal from the GFC. Water transport mechanisms through the membrane are well known in literature, but typically a high computational burden is requested for their proper simulation. To deal with this issue, the authors have developed an analytical model for the water membrane content simulation as function of stack temperature and current density, for fast on-board monitoring and control purposes, with good fit with literature data. The water flow from the catalyst layer to the GFC through the GDL is modelled
Sicilia, Massimo, Cervone, Davide, Polverino, Pierpaolo, Pianese, Cesare
Technical Paper
Aitiip Integrates Freeform Injection Molding to Lower Weight and Reduce Production Costs24AERP06_0206/01/2024
Aitiip is a leading Spanish research and development institute and serves companies in the aeronautics, automation, industrial, and packaging sectors. The institute possesses strong platforms for the characterization of materials and processes and is known as a powerful integrator of technologies, which is constantly on the lookout for the next transformative technology. A year ago, Aitiip implemented an NXE 400 industrial resin 3D printer platform from Nexa3D to explore integrations of additive manufacturing and injection molding. Nexa3D is the Ventura, California-based provider of high-speed industrial printing technologies whose portfolio continues to grow, reflected in its acquisition of Essentium, one of the world's most well-known providers of extrusion 3D printing, earlier this year. Liebherr is one of the world's largest providers of a variety of industrial goods, services and products. Aerospace and transportation systems is one of 13 different product segments supplied by the
Magazine Article
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