Browse Topic: Forming

Items (5,429)

Development of Integrated Forming of New "NMAX" YECVT Parts Using the Plate Forging Method

2025-32-0005To be published on 11/03/2025

Yamaha Motor Engineering Co., Ltd. provides plastic processing technology based on fuel tank press forming technology, and is developing various plastic processing methods, including forging, and developing mold equipment to realize them. This time, the core parts of the YECVT unit mounted on Yamaha Motor Co., Ltd.'s small premium scooter "NMAX" were not made by welding individual parts to each other, but by integrally forming them from a single thick plate using the cold forming method, resulting in lightweight, compact, high-strength, high-precision parts. By incorporating a composite plastic processing method that takes advantage of the characteristics of the material while making full use of analysis technology and mold technology, we were able to develop a composite plastic processing method (plate forging method) that creates new added value and mass produce it. In addition,this development has made it possible to achieve a thickness increase of 1.7 times the standard material

Hongo, Hironari, Tamaru, Shogo, Uda, Shinnosuke

Aluminum Alloy, Extrusion 2.7Cu - 1.8Li - 0.7Zn - 0.3Mn - 0.3Mg - 0.08Zr (2099-T81) Solution Heat Treated, Stress Relieved by Stretching 1 to 3% and Aged

AMS4459C (Current)

07/22/2025

This specification covers an aluminum alloy in the form of extruded bars, rods, and profiles (shapes) from 0.375 to 1.300 inches (9.53 to 33.02 mm) in diameter or thickness, produced with cross-sectional area of 22.5 square inches (145 cm2), maximum, and a circumscribing circle diameter (circle size) of 17.4 inches (44.2 cm), maximum (see 2.4 and 8.8).

AMS D Nonferrous Alloys Committee

O-Ring Machined from AMS3617 Material

AS9772A (Current)

07/17/2025

This standard establishes the dimensional and visual quality requirements, lot requirements, and packaging and labeling requirements for O-rings machined from AMS3617 polyamide material. It shall be used for procurement purposes.

A-6C2 Seals Committee

Manufacturing and Inspection Standards for Preformed Packings (O-Rings)

AS871B (Current)

07/16/2025

This specification controls surface condition, manufacturing defects and inspection requirements, and defines methods of measurement for elastomeric toroidal sealing rings (O-rings) for static (including gasket) applications.

A-6C2 Seals Committee

Nickel Alloy, Corrosion- and Heat-Resistant, Investment Castings 47.5Ni - 22Cr - 1.5Co - 9Mo - 0.60W - 18.5Fe (Hastelloy® X) As-Cast

AMS5390H (Current)

07/16/2025

This specification covers a corrosion- and heat-resistant nickel alloy in the form of investment castings.

AMS F Corrosion and Heat Resistant Alloys Committee

Nickel Alloy, Corrosion- and Heat-Resistant, Investment Castings 73Ni - 0.14C - 13Cr - 4.5Mo - 2.3Cb (Nb) - 0.75Ti - 6.0Al - 0.010B - 0.10Zr (IN-713) Vacuum Cast, As-Cast

AMS5391J (Current)

07/16/2025

This specification covers a corrosion- and heat-resistant nickel alloy in the form of investment castings.

AMS F Corrosion and Heat Resistant Alloys Committee

Alloy, Corrosion- and Heat-Resistant, Investment Castings 30Fe - 21Cr - 20Ni - 20Co - 3.0Mo - 2.5W - 1.0Cb - 0.15N (N-155) As-Cast

AMS5376J (Current)

07/16/2025

This specification covers a corrosion- and heat-resistant iron alloy in the form of investment castings.

AMS F Corrosion and Heat Resistant Alloys Committee

In Situ Observation of Different Soot Layers in a Model Filter Channel during Its Regeneration

2025-01-0312

07/02/2025

In order to comply with increasingly stringent emission regulations and ensure clean air, wall-flow particulate filters are predominantly used in exhaust gas aftertreatment systems of combustion engines to remove reactive soot and inert ash particles from exhaust gases. These filters consist of parallel porous channels with alternately closed ends, effectively separating particles by forming a layer on the filter surface. However, the accumulated particulate layer increases the pressure drop across the filter, requiring periodic filter regeneration. During regeneration, soot oxidation breaks up the particulate layer, while resuspension and transport of individual agglomerates can occur. These phenomena are influenced by gas temperature and velocity, as well as by the dispersity and reactivity of the soot particles. Renewable and biomass based fuels can produce different types of soot with different reactivities and dispersities. Therefore, this study focuses on the influences of soot

Desens, Ole, Hagen, Fabian P., Meyer, Jörg, Dittler, Achim

Welded, Flash-Controlled, Low-Carbon Steel Tubing Normalized for Bending, Double Flaring, Beading, Forming, and Brazing

J356_202506 (Current)

06/30/2025

This SAE Standard covers normalized electric-resistance welded flash-controlled single-wall, low-carbon steel pressure tubing intended for use as pressure lines and in other applications requiring tubing of a quality suitable for bending, double flaring, beading, forming, and brazing. Material produced to this specification is not intended to be used for single flare applications, due to the potential leak path caused by the Inside Diameter (ID) weld bead or scarfed region. Assumption of risks when using this material for single flare applications shall be defined by agreement between the producer and purchaser. This specification also covers SAE J356 Type-A tubing. The mechanical properties and performance requirements of SAE J356 and SAE J356 Type-A are the same. The SAE J356 or SAE J356 Type-A designation define unique manufacturing differences between coiled and straight material. Nominal reference working pressures for this tubing are listed in ISO 10763 for metric tubing, and SAE

Metallic Tubing Committee

Nonlinear Finite Element Calculation of Ultimate Breakage Load for Pyro-Inflator Housing

2025-01-5045

06/27/2025

Accurate prediction of the ultimate breakage pressure load for pyro-inflator housing is a critical aspect of inflator development. In this study, the tensile test of a specimen, from its initial shape to fracture, is simulated to verify the material properties of the inflator housing. The numerical results demonstrate high accuracy, with the tensile force–displacement curve, maximum tensile force, necking in the concentrated instability zone, fracture location, and inclined angle all closely matching the experimental data. Following material correlation, the ultimate breakage load of the inflator housing under hydrostatic burst test conditions is calculated using an explicit solver. A stress tensor state analysis method is proposed to define the ultimate load based on the onset of plastic instability in the thickness direction at the top center of the inflator. Compared to experimental results, the accuracy of the ultimate breakage pressure prediction using this method is 99.04%, while

Wang, Cheng

Effect of Copper on Extrudability of High-Strength AA6082 Aluminum Alloys

05-19-02-0010

06/19/2025

There is a critical need to understand and optimize the extrudability of AA6xxx alloys, which are widely used in industries such as automotive and aerospace due to their favorable combination of strength, formability, and corrosion resistance. Surface cracking during the extrusion process remains a significant challenge, compromising the material’s mechanical properties and product quality. While previous studies have investigated surface cracking using various techniques, the underlying mechanisms remain elusive, especially regarding the role of important alloying elements such as copper. Therefore, this research provides a thorough investigation of the effect of copper additions on the solidus temperature, hot deformation behavior, and extrudability of AA6xxx alloys. Using experimental and numerical methods, the material’s solidus temperature and constitutive behavior were determined. Extrusion trials were conducted for alloys with different copper levels using a flat die over a

Wang, Xiaoying, Shehryar Khan, Muhammad, Wells, Mary A., Poole, Warren J., Parson, Nick

Aluminum Alloy, Extrusions 4.5Cu - 0.85Si - 0.80Mn - 0.50Mg (2014-T6) Solution and Precipitation Heat Treated

AMS4153N (Current)

06/17/2025

This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing up to 32 square inches (206 cm2) in area (see 8.6).

AMS D Nonferrous Alloys Committee

Improving the Sound Transmission Loss of Wire Harness Pass Throughs

2025-01-0118

05/05/2025

For years the NVH community has known that openings in the dash sheet metal, such as holes to pass wire harnesses through, creates an acoustical weak point that limits the potential noise reduction of the dash insulation system. These pass-throughs can also be a source of water leaks into the vehicle’s interior. With internal combustion engines and now electric inverter power plants generating significant high frequency sound, the need to seal this area is vital. By molding a lightweight barrier that draws through the fiber/absorber interior decoupler and dash sheet metal which mates to a secondary seal molded into an outer engine dash decoupler, the two opposing molded barriers meet in the engine compartment and compress together forming a seal around the wire harness. This male/female molded seal replaces the conventional snap in grommet and eliminates noise/water leaks. The system Sound Transmission Loss (STL) is equivalent to similarly insulated sheet metal with no holes

Check, James, Moritz, Charles

New System for the Measurement of Sound-Insertion Loss on Small Samples: A Comparison with ASTM-E2611 and ASTM E90 Test Procedures

2025-01-0116

05/05/2025

This article follows a companion article [1] presented at the SAE NVC 2021, in which a new system for the measurement on small samples of the normal-incidence Insertion Loss (IL) of multilayers used for the manufacturing of automotive sound package parts was first introduced. In addition to simplifying the evaluation of the sound-insulation of multi-layers used to produce sound-package components, the system aims at overcoming the limitations of the test procedure based on the ASTM E2611 standard. In this article, the latter point is demonstrated by comparing the insertion loss results obtained with the new system with those obtained with the test procedure based on the ASTM E2611 standard on a few multilayers commonly used for the manufacturing of automotive sound package parts. Results indicate that the data obtained by means of the newly developed system are more meaningful, practically usable and less prone to edge-effects, compared to those obtained according to the ASTM E2611

Ruggeri, Giulio, Bertolini, Claudio, Horak, Jan

Drilling Methods for Controlling Exit Burr Height in CRES Material Stacks

2025-01-0169

05/02/2025

The Electroimpact Automatic Fan Cowl Riveter uses two novel drill processes to control exit burr height and achieve the required hole quality in CRES (Corrosion-Resistant Steel, also called stainless steel) material stacks. Both processes use piloted cutters on the OML (Outer Mold Line, referring to the exterior surface of an airframe) side, and two different tools are used in a backside spindle on the IML (Inner Mold Line, referring to the inside surface of an airframe) side of the component. The first process uses a shallow-angle shave tool in the IML spindle to directly control the exit burr height after it is produced by the OML spindle and is called the “burr shave” technique. The second process uses a countersink tool in the IML spindle and produces an “intermediate countersink” after the pilot hole is drilled by the OML spindle, but before the final hole diameter is drilled. These drill processes were able to achieve the required hole quality in a challenging CRES material stack

Schultz, Rich, Peterman, Randy, Luker, Zachary, Murakonda, Sai Krishna

Comparison of Different Joining Techniques as a Benchmark for Integrally Joined Thermoformed Components Based on Tailored rCF Organosheets

2025-01-0170

05/02/2025

Climate-neutral aviation requires resource-efficient composite manufacturing technologies and solutions for the reuse of carbon fibers (CF). In this context, thermoplastic composites (TPC) can make a strong contribution. Thermoforming of TPC is an efficient and established process for aerospace components. Its efficiency could be further increased by integration of joining processes, which would otherwise be separate processes requiring additional time and equipment. In this work, an integrative two-step thermoforming process for hollow box structures is presented. The starting point are two organosheets, i.e. fiber-reinforced thermoplastic sheets. First, one of the organosheets, intended for the bottom skin of the uplift structure, is thermoformed. After cooling, the press opens, the organosheet remains in the press and an infrared heater is pivoted in, to locally heat up just the joining area. Meanwhile, a second organosheet, intended for the top skin, is heated and thermoformed and

Vocke, Richard, Seeßelberg, Lorenz, Focke, Oliver, Dietrich, Jan Yorrick, Jobke, Katrin, Albe, Christopher, May, David

Predicting Forming Limit of Hot Stamping Boron Steel Using a Modified Zener-Hollomon Parameter based Ductile Failure Criterion

2025-01-8225

04/01/2025

Combined with a modified Zener-Hollmon parameter, a recently proposed ductile failure criterion is further improved to predict the forming limit of boron steel at hot stamping temperatures. The ductile failure criterion takes into account the critical damage at localized necking or at fracture as a function of strain path and initial sheet thickness. The modified Zener-Hollomon parameter accounts for both effect of varying strain rate and temperature for Boron steel. Working FEM simulation, the capability of the ductile failure criterion is further demonstrated by predicting forming limit of a boron steel in an isothermal Nakajima dome test. Comparison shows the prediction matches quite well with the measurement.

Sheng, ZiQiang, Mallick, Pankaj

A New Methodology to Characterize the Influence of Paint Baking and Pre-Straining on the Tensile Properties of Third Generation Advanced High Strength Steels

2025-01-8223

04/01/2025

The current ASTM A653 standard for determining the bake hardening index (BHI) of sheet metals can lead to premature fracture at the transition radius of the tensile specimen in high strength steel grades. In this study, a new test procedure to characterize the BHI was developed and applied to 980 and 1180 MPa third generation advanced high strength steels (3G-AHSS). The so-called KS-1B methodology involves pre-straining over-sized tensile specimens followed by the extraction of an ASTM E8 sample, paint baking and re-testing to determine the BHI. Various pre-strain levels in the range of 2 to 10% were considered to evaluate the KS-1B procedure with select comparisons with the ASTM A653 methodology for pre-strain levels of 2 and 8%. Finally, to characterize the influence of paint baking at large strain levels, sheared edge conical hole expansion tests were conducted. The tensile mechanical properties of the 3G steels after paint baking were observed to be sensitive to the pre-strain with

Northcote, Rhys, Berry, Avalon, Narayanan, Advaith, Tolton, Cameron, Lee, Haea, Smith, Jonathan, McCarty, Eric, Butcher, Cliff

Understanding Forming Characteristics of Different Microstructure Steels within 980MPa and 1180MPa

2025-01-8222

04/01/2025

For electrical vehicle (EV) automotive body-in-white (BIW) structures, protection of passengers and battery in crash event becomes equally important. In addition to energy absorption, intrusion protection for battery and vehicle becomes extremely important and GPa advanced high strength steels (AHSS) including press hardened steels (PHS), DP/MP/CP/GEN3 steels have become material of choice for design for those components. Higher yield strength materials especially in 980/1180MPa MP and CP category are chosen for part design over conventional low yield strength DP. In this study, the forming characteristics including both global and local formability are evaluated and compared among 980 DP/MP grades. Formability test such as forming limit curve (FLC), true fracture strain, V bend, half dome, and hole expansion tests are conducted. Microstructure analysis to understand the effect of different grain structure and phases of DP/MP grades is also accomplished. A T-shape laboratory die trials

Shih, Hua-Chu, Pednekar, Vasant, Shi, Ming, Singh, Jatinder, Tedesco, Sarah, Wu, Wei

NdFeB Magnets Manufactured by Hot Pressing Using Strip-Cast and Melt-Spun Powders

2025-01-8217

04/01/2025

The initial powder used for the manufacturing of NdFeB permanent magnets is usually prepared through rapid cooling, either by melt spinning or strip casting. The powders produced by these two methods are suitable for different applications: while melt-spun powder is a good initial material for bonded and hot-deformed magnets, strip-cast powder is normally used for sintered magnets. To investigate the suitability of using strip-cast powder to manufacture hot-deformed magnets, NdFeB powder prepared by strip casting was hot pressed (without particle alignment) and compared with melt-spun powder prepared under the same conditions (700 °C, 45 MPa, 90 min). Although the processing parameters are the same (pressed in the same mold), the magnetic properties of the magnets made from the two powders are significantly different. Surprisingly, the magnet made from the strip-cast powder (after ball milling) shows comparable magnetic properties to those of isotropic magnets, with coercivity (HcJ) of

He, Youliang, Song, Shaochang, Walsh, Dan, Bernier, Fabrice, Mozharivskyj, Yurij, Peng, Philip

Deformation Behavior and Springback Analysis of Anti-Collision Beam on Bending Forming

2025-01-8247

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 bumper 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 process

Zhang, Shizhen, Meng, Dejian, Gao, Yunkai

Zero Circumferential Material Flow Line-Based Method for Reducing Stamping Simulation Cost

2025-01-8224

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

A Review of Warm Forming for Steels: History, Methodology and Emerging Trends

2025-01-8814

04/01/2025

Many manufacturing techniques and processes 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 re-evaluation of less-used metal forming technologies, such as warm forming and sheet hydroforming for steel are responses 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 (above or 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 thorough summary of the effect of elevated temperatures on various grades of steel. Different heating techniques, their cycle times and effects on final forming feasibility are contrasted. The effect of chemistry

Kella, Caroline, Wormald, Tom

Finite Element Simulation and Experimental Study of the in-Mold Graining Process

2025-01-8330

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 forming process. Numerical simulation of the vacuum forming process of TPO material is conducted using

Chai, Bingji, Guo, Yiming, Xie, Xinxing, Zhang, Qu

Multi-objective Optimization of Process Parameters for Dual-Color Injection Molding of the Middle Cover of Electric Vehicle Charging Pile

05-18-04-0031

03/26/2025

This article takes the cover of the AC charging pile as the research object and studies the process parameters of dual-color injection molding. First, the optimal Latin hypercube experimental design is carried out by using optimization software by taking the melt temperature and mold temperature of the first shot and the second shot and the holding pressure as the influencing factors. Injection simulation is carried out based on mold flow software. A high-precision neural network model RBF is constructed according to the test factors and results. Second, based on the obtained RBF prediction model, the multi-objective NSGA-II algorithm is used for optimization. The obtained optimal combination of molding process parameters is: the melt temperature of the first shot is 266.8°C, the mold temperature is 107°C, the melt temperature of the second shot is 230.3°C, the mold temperature is 59.5°C, the holding pressure of the first shot is 95 MPa, the holding pressure of the second shot is 89.9

Liu, Hao, Jiang, Bingyun, Jiang, Hong, Hu, Peng, Cheng, Shan

Aluminum Alloy, Extrusions, 4.4Cu - 1.5Mg - 0.60Mn (2024-T3511), Solution Heat Treated, Cold Worked, Stress-Relieved by Stretching, and Straightened

AMS4165K (Current)

03/25/2025

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

Aluminum Alloy, Extrusions, 4.4Cu - 1.5Mg - 0.60Mn (2024-T3510), Solution Heat Treated, Cold Worked, Stress-Relieved by Stretching, Unstraightened

AMS4164K (Current)

03/25/2025

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

Aluminum Alloy Extrusions, 4.4Cu - 1.5Mg - 0.60Mn (2024-T3), Solution Heat Treated and Cold Worked

AMS4152P (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

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 Aged

AMS4287C (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

Quantifying Hydroplaning Risk: Insights from Water Film Thickness Measurements on Maryland Highways

02-18-02-0010

02/19/2025

Wet pavement conditions during rainfall present significant challenges to traffic safety by reducing tire–road friction and increasing the risk of hydroplaning. During high-intensity rain events, the roadway pavement tends to accumulate water, forming a film that can have serious implications for vehicle control. As the longitudinal speed of the vehicle increases, a water wedge forms in front of the tire, leading to partial loss of contact with the road. At critical hydroplaning speed, a complete water layer forms between the tire and the road. Although less common, dynamic hydroplaning poses severe risks when high-intensity rainfall coincides with high vehicle traveling speed, leading to a complete loss of control over vehicle steering capabilities. This study advances hydroplaning research by integrating real-world data from the Road Weather Information System (RWIS) with an existing hydroplaning model. This approach provides more accurate hydroplaning risk assessments, emphasizing

Vilsan, Alexandru, Sandu, Corina, Anghelache, Gabriel

Evaluating Cone and Pyramid Frustums with Constant and Varying Wall Angles in Single-Point Incremental Sheet Forming

05-18-03-0019

02/07/2025

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

Utilizing High-Performance Thermoplastics to Improve Durability and Efficiency in Automotive Instrument Panels

2024-01-5245

01/28/2025

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.

Aluminum Alloy, Extrusions, 4.4Cu - 1.5Mg - 0.60Mn (2024-T81), Solution Heat Treated, Cold Worked, and Precipitation Heat Treated

AMS4491A (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

Aluminum Alloy, Extrusions, 4.4Cu - 1.5Mg - 0.60Mn (2024-T8511), Solution Heat Treated, Cold Worked, Stress-Relieved by Stretching, Precipitation Heat Treated, and Straightened

AMS4423A (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

Nickel-Iron Alloy, Magnetic, Sheet and Strip 50Ni - 50Fe Stamping Quality, Half-Hard Temper

AMS7719F (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

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 Aged

AMS4257A (Current)

01/22/2025

This specification covers an aluminum alloy in the form of extruded bars, rods, and profiles.

AMS D Nonferrous Alloys Committee

Nickel-Iron Alloy, Magnetic, Sheet and Strip 50Ni - 50Fe Annealed, Forming Grade

AMS7717F (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

Superfinishing of HVOF Applied Tungsten Carbide Coatings

AMS2452 (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

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 Overaged

AMS4617B (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

Effect of Nano Silica on the Mechanical Behaviour of High Impact Polypropylene/Nano Clay Composites

2024-01-5211

12/10/2024

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.

Efficient Robot Roller Hemming Process Using Turntable over Linear Setup

2024-28-0164

12/05/2024

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

Optimizing the Capacity of Dozer Blade with Hydraulic Foldable Wings to Enhance Productivity

2024-28-0268

12/05/2024

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

Microstructural Characterization of Aluminium Alloys Used in Automotive Body Parts

2024-28-0157

12/05/2024

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

Magnesium Alloy, Extrusions, 4.0Y - 2.25Nd - 0.5Zr (WE43C - T5), Precipitation Heat Treated

AMS4485B (Current)

12/04/2024

AMS D Nonferrous Alloys Committee

Aluminum Alloy, Extrusions, 4.4Cu - 1.5Mg - 0.60Mn (2024-T8510), Solution Heat Treated, Cold Worked, Stress-Relieved by Stretching, and Precipitation Heat Treated, Unstraightened

AMS4481A (Current)

12/04/2024

AMS D Nonferrous Alloys Committee

Aluminum Alloy, Extrusions, 4.4Cu - 1.5Mg - 0.60Mn (2024-O), Annealed

AMS4421A (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

Maximizing the Potential of TPU Extrusion in Medical Tubing Applications

TBMG-52164

12/01/2024

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.

Development of a Robot-Assisted Fused Deposition Modeling Process for Enhanced Additive Manufacturing

05-18-02-0011

11/09/2024

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

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

Aluminum Alloy, Discontinuously Reinforced Extruded Bar, Rod, Wire and Shapes, 2124A/SiC/25p (3 µm) - T1P

AMS4379A (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

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