Browse Topic: Joining

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Optimizing joint efficiency in stainless steel-aluminum alloy FSW joints through advanced parameter control2026-01-0228To be published on 04/07/2026
The present work investigates the friction stir welding (FSW) of dissimilar materials, specifically stainless steel 304 and aluminum alloy AA2024-T3, to analyze their tensile strength behavior. The significant challenges inherent in joining these materials, stemming from their vastly divergent thermal and mechanical properties, are addressed through a structured experimental and statistical methodology. The L18 Taguchi mixed orthogonal array was employed to systematically evaluate the influence of three critical process parameters: tool rotational speed, welding speed, and tool pin offset. Eighteen experimental trials were conducted using a butt joint configuration. The analysis identified tool rotational speed as the most influential parameter affecting the joint integrity. A combination of 450 rpm rotational speed, 20 mm/min welding speed, and a 1.5 mm pin offset toward the aluminum side yielded the optimum results, achieving a peak ultimate tensile strength (UTS) of 344.7 MPa and a
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 FSW2026-01-0229To be published on 04/07/2026
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 refinement of grain 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
Ahmad, Tariq, Khan, Noor Zaman, Ahmad, Babar, Siddiquee, Arshad Noor
Multi-Joint Topology Optimization Method with Interface Geometry Control2026-01-0503To be published on 04/07/2026
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, Kim, Il Yong
Conjugate Heat Transfer Modeling for Predicting Thermal Behavior of X76 Emotor Windings2026-01-0118To be published on 04/07/2026
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
A Study on Fatigue Life Prediction Method for Point-Based Joints Considering Multiple Fracture Modes – FDS, Blind Rivet, and Blind Nut Focus2026-01-0180To be published on 04/07/2026
The application of light weight alloys for vehicle bodies such as aluminum alloys and composite materials are rapidly advancing to support the construction of multi-material vehicle bodies. 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 introduces new challenges in manufacturing, particularly in joining technologies. Since different materials have varying mechanical properties, thermal behaviors, and surface characteristics, selecting appropriate joining methods is essential to ensure structural integrity and durability. Depending on the material types, thicknesses, production processes, and cost constraints, various joining techniques—such as
Takuno, Sougo, Isono, Toshiyuki, Urakawa, Kazushi, Goto, Suguru, Kawamura, Hiroaki, Niisato, Eita, Ishigami, Yuta
Optimizing Weld Placement in Automotive Structures Using Topology and Multi-Disciplinary Approaches2026-01-0514To be published on 04/07/2026
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
Lightweight Bubble Sheet Panel To Reduce Inverter Noise and Vibration for Electric Vehicles2026-01-0442To be published on 04/07/2026
Inverters are typically integrated into electric drive units for electric vehicles (EVs) to reduce packaging size and cost. However, coupled vibrations from the electric motor and gears are transmitted to the inverter, which, due to its large radiative panel, becomes a dominant noise source. Metal panels are required for electromagnetic interference (EMI) compliance, yet these covers usually lack sufficient stiffness or damping for noise control. Adding ribs and applying damping treatments results in excessive mass, cost, and packaging challenges. A new, patented bubble sheet panel design has been developed to enhance the structural strength and damping of the inverter while significantly reducing its mass. A thin sheet of aluminum or magnesium is welded onto the cover in an optimized pattern that enhances stiffness and damping performance while accommodating packaging requirements. The welding pattern can include logos or artistic designs to improve the panel’s appearance. The metal
He, Song, Bobel, Andrew, Naismith, Gregory, Yi, Wenwen, Patruni, Pavan Kumar
Effective Prediction of the Mechanical Properties of Glue-Laminated Motor Core with consideration of glue disposition and stacking factor.2026-01-0177To be published on 04/07/2026
This study presents a practical approach for predicting the mechanical properties of glue-laminated motor cores, with a particular focus on the influence of glue disposition patterns and coverage rate, to enable more accurate material modeling and reliable NVH and other general structural analysis. Since glue bonding and lamination stacking are essential for ensuring the structural integrity of motor stator cores, variations in glue implementation introduce significant changes in both in-plane and out-of-plane stiffness properties. To address this, a homogenization framework based on the unit-cell method, considering detailed glue application information, is employed. The laminated structure is idealized as an orthotropic material, and the variation of in-plane properties in different directions is considered. Unlike simplified coverage-rate models, the proposed method incorporates localized glue distribution patterns—such as teeth, core back iron, and edge-concentrated regions like
Nie, Zifeng
A Novel Spot Joint Element for Fatigue Evaluation of Spot Welds and Fasteners in Lightweight Automotive Structures2026-01-0182To be published on 04/07/2026
Due to the spot weld and mechanical fastener share the similar characteristics to join sheets together with only 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 peripheral 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
Wu, Shengjia, Zhang, Lunyu, Dong, Pingsha
Integrated Welding Simulation and Experimental Characterization of Weld-Metal and Heat-Affected-Zone Strength in AA6063-T62026-01-0230To be published on 04/07/2026
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
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
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
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
Aerospace & Defense Technology: February 202626AERP022/5/2026
Plasma Surface Activation for Stronger, More Durable CFRP Bonds in Aerospace Smarter Pyrovalve Alternatives for Modern Missile and Munition Launcher Applications Aerospace Aluminum Laser Welding: Advancing Material Performance for the Future of Flight Model-Based Design Is Shaping the Next Phase of eVTOL Systems Development How RF-over-Fiber is Providing the Backbone of Next Generation Mil/Aero Networks NASA Demonstrates a First-of-Its-Kind Space Communications A Rainfield Simulator for Hypersonic Testing The U.S. Army Space and Missile Defense Command Technical Center's Aerophysics Research Facility, (ARF), fired a successful hypersonic shot to test its new rainfield simulator. Next Generation Carbon Fiber Composites 3D Printer for Hypersonic Research Auburn University's Applied Research Institute in Huntsville is adding some serious fiber to its diet. The Critical Impact Of SAE Aerospace Standards: Certified AS1895/7 and /23 Metal Seals How engineers can ensure safety, reliability
Aerospace Aluminum Laser Welding: Advancing Material Performance for the Future of Flight26AERP02_032/1/2026
Between the 1920s and 1930s, aluminum started replacing wood as the primary material in aircraft construction and soon became the backbone of modern aviation. Its popularity stemmed from a combination of properties, high strength-to-weight ratio, corrosion resistance, and ease of forming that made it ideal for demanding aerospace applications. Throughout much of the 20th century, high-strength aluminum alloys dominated aircraft design, accounting for 70-80 percent of commercial airframes and more than half of many military aircraft. Even after the introduction of fiber-polymer composites in the early 2000s, aluminum has remained a critical material because it continues to offer the strength, lightness, and versatility needed for modern aviation. Industry forecasts predict that commercial air travel will double in the next 25 years, which means more pollution will be released into the atmosphere. One way to help reduce these emissions is by building airplane fuselages and wings with
Plasma Surface Activation for Stronger, More Durable CFRP Bonds in Aerospace26AERP02_012/1/2026
Carbon fiber-reinforced polymers (CFRPs) have become essential in modern aerospace structures, from fuselage skins and wing components to nacelles, interior structures, and a growing range of primary load-bearing parts. Their high strength-to-weight ratio delivers major benefits in fuel efficiency, payload capacity, and fatigue performance. Yet achieving reliable adhesive bonds on CFRP surfaces remains a persistent engineering challenge. The low intrinsic surface energy of composites - particularly under thermal cycling, vibration, and moisture exposure - limits bond durability unless surfaces are properly prepared. Plasma surface treatment has emerged as a pivotal solution, offering a fast, controllable, and non-destructive way to increase surface energy, improve wettability, and enhance adhesion across complex geometries. This is especially important as the aerospace industry transitions from thermoset to thermoplastic composites (TPCs), which enable faster processing, lower
Failure Analysis of Dissimilar Metal Weld Joint of an Air Spring Bracket within an Automotive Active Seat Suspension System2026-26-04871/16/2026
In modern four-wheelers, seat suspension systems play a crucial role in enhancing occupant comfort by mitigating the effects of road unevenness and vibrations. Among these systems, active suspension mechanisms offer advanced performance through complex assemblies involving welded, riveted, and bolted joints. This study investigates the failure of an air spring bracket - a critical component of a pneumatic active suspension system - manufactured by Gas Metal Arc Welding (GMAW) of two dissimilar ferrous materials which are likely to be SAPH440 and S355J2. These different materials were used based on mechanical properties required to perform by their particular part. System level validation tests were conducted to ensure the reliability of the seat suspension system. The one of the validation tests is continuous cyclic fatigue test which is carried out on the complete seat assembly. However, during vibration / cyclic endurance testing, premature failures were observed near the weld joints
Patale Jr, Reshma, Pinjari, Jayant Namdev, Bali, Shirish
Numerical Investigation on Thermo-Mechanical Characteristics of Injection-Molded Thermoplastics using Anisotropic Material Properties2026-26-02801/16/2026
This paper presents a comprehensive numerical methodology for simulating the coupled process-structure behavior of short glass fiber-reinforced, injection-molded thermoplastics. The approach integrates elastoplastic and anisotropic material characteristics using three engineering tools: Moldflow, Digimat, and ABAQUS. It accounts for fiber orientation and injection molding defects, linking to thermo-mechanical performance. This method enables accurate virtual modeling of real-time injection-molded components by transferring anisotropic data from Moldflow to ABAQUS. In this study, short fiber orientation and potential injection molding defects such as weld lines and residual stresses are discussed using Moldflow simulation. Besides, Digimat is employed as an interface tool to facilitate the transfer of Moldflow simulation results, namely fiber orientation and material behavior in the allied configurations directly into ABAQUS. This integration enables the evaluation of thermo-mechanical
T, Kalinga, Yanamadala, Dharma Teja, Mattupalli, Venkata, Chirravuri, Bhaskara, Miller, Ronald
Advanced Welding Process Simulation for Prediction and Control of Distortion and Residual Stresses in Automotive Sheet Metal Component Assembly2026-26-04121/16/2026
Welding simulations are transforming industrial manufacturing by enabling a predictive and first-time-right approach for process development. Advanced techniques such as Finite Element Analysis (FEA) help in accurate prediction of temperature distribution, residual stress, distortions and potential defects prior to physical welding which in turn support for addressing key challenges associated with Heat Affected Zones (HAZ) like distortion, fitment issues and post-weld cracking. Early integration of simulation in the development cycle significantly reduces lead time, enhances durability, and improves manufacturing efficiency. This study presents a simulation-based product development approach to mitigate post-weld crack generation issues in a complex multiple weld configuration of an automotive sheet metal assembly. The methodology adopts a two-stage framework: first, identifying the root cause of crack generating through baseline weld simulation; and second, implementing design
Nalawade, Rahul, Deshmukh, Kishor Pandurang, Vidhate, Digambar, Prakash, Ved, Dabhadkar, Mandar Mukund
Study of Style Wheel Rim Failure Due to Rim and Disc Assembly Interference2026-26-05411/16/2026
This study focuses on the investigation of wheel rim failures near weld zone during repeated cornering induced by interference between the rim and disc during the wheel manufacturing assembly process. Strain gauges were employed to capture real-time stress and strain distributions at critical zones during interference fitting. The experimental results revealed that improper interference levels lead to significant stress concentrations, often surpassing the material's elastic limit, initiating micro-crack formation and promoting fatigue failure. Detailed strain analysis indicated that both radial and axial stresses contribute to long-term structural degradation. The study highlights the critical role of dimensional tolerances, surface finishes, and assembly forces in minimizing stress-induced failures. Recommendations are provided for optimizing design and assembly practices to enhance the durability and reliability of automotive wheels.
P, Praveen, DEsigan, Lakshmipathy, K, Chandramohan, C, Santhosh
Effect of Pipe Bending by Rotary Tube Bending Process on Durability of Frame Structure2026-26-03701/16/2026
Automobile frames, particularly trellis frame structures, are engineered for superior dynamic performance, with stiffness being a paramount consideration1. These frames frequently utilize welded tubes, a manufacturing process made more complex by the necessity of bending tubes to precise angles to meet packaging and assembly requirements2. This bending, however, induces residual stresses that can substantially compromise the frame's durability3. This investigation employs a detailed finite element simulation to analyse the structural deformation and residual stresses that arise during the bending of Cold Electric Welded (CEW) annealed round pipes4. A comprehensive 3D mechanical model, incorporating realistic tooling and contact interactions, was developed to accurately simulate shape change, ovality, and wall thickness redistribution during the bending process5. CEW pipes, unlike their Electric Resistance Welded (ERW) counterparts, possess minimal initial forming stresses, and the
Rajwani, Ishwar, Khare, Saharash
Tailgate Stiffness Mitigation and Engineering Strategy for Full Width Tailgate-Mounted Tail Lamp Integration2026-26-04941/16/2026
The tailgate, as the rearmost vehicle opening, plays a pivotal role in defining the rear aesthetic theme while ensuring structural durability and maximizing luggage space. Contemporary automotive design trends highlight an increasing demand for Full width tailgate-mounted tail lamp configurations, which deliver a bold and dynamic visual appeal. Enhanced by animated lighting features, these designs cater to the preferences of Gen Z customers, becoming a decisive factor in purchasing decisions. However, integrating these complex tail lamp structures introduces significant engineering challenges, including increased X-dimension lamp volume, thereby providing reduced design space, and intricate mounting schemes constrained by panel stamping limitations. These factors necessitate the development of innovative joinery strategies and structural definitions to maintain durability targets, including achieving 25,000–30,000 slam cycles without failure, while preserving luggage space. This paper
Beryl, Joshua, Mohanty, Abhinab, Unadkat, Siddharth, Selvan, Veera
Advancing Welding Excellence Through Numerical Simulation Based Approach: A Multi Pass Welding Case Study on Cast Iron Coupons2026-26-04571/16/2026
The Automotive industry widely uses cast iron due to its better mechanical performance and cost-effectiveness. However, repair welding or assembly of cast iron components remain highly challenging due to the material’s high carbon content, inherent brittleness, rapid thermal conductivity, and complex microstructural transformations. Multi-pass welding exacerbates these challenges by subjecting materials to repeated thermal cycling, accumulating residual stress, and inducing distortion – all of which potentially degrade the integrity of welded joints. A comprehensive understanding of welded joint behavior is essential to effectively mitigate these effects. Finite element analysis (FEA) serves as a powerful tool, enabling accurate prediction of thermal profiles, phase transformations, residual stress development, and resulting deformations. These valuable insights are critical for optimizing welding processes and enhancing overall joint quality. This study investigates and validates the
Vidhate, Digambar, Nalawade, Rahul, Dabhadkar, Mandar, Vaidya, Abhijit, Ammasi, Vinoth, Rajagopalan, Sridhar
Study the Tool Profile and Rotational Speed on Mechanical Attributes of FSW of Al 6063 Alloy05-19-03-00231/12/2026
Friction stir welding (FSW) of Al 6063 alloy plates of 6 mm thickness was investigated in the present study for exploring the mechanical attributes of the welded joints. The tool profile significantly influences the quality of joints produced by FSW. In the current study, the influence of tool profile and FSW process parameters on the FSW weld characteristics of similar joining of Al 6063 plates has been investigated. The effect of FSW tool rotational speed (TRS) and tool travel speed on the FSW weld properties, mainly microstructure characteristics, microhardness, and ultimate tensile strength (UTS), have been studied. Comparison of two different tool profiles, namely taper and cylindrical tool, has also been examined. The effect of transient temperature distribution has also been studied for varying FSW process parameters. When increasing the tool’s rotational speed from 800 to 1200 rpm at a fixed traverse speed of 80 mm/min, a rise in peak temperature is observed. Conversely
Kumar, Pramod, Kumar, Vikash, Kumar, Gulshan, Arif, Abdul, Prasad, Chitturi Ram, Zubairuddin, M.
Advances in Fiber Laser Welding for E-Mobility ManufacturingTBMG-544331/1/2026
High-power fiber lasers have become increasingly indispensable tools in automotive manufacturing over the past two decades. They are now widely deployed in welding and brazing applications for body-in-white, powertrains, engine components, and more.
Influence of Microstructure on the Mechanical Properties of Laser-Welded Joints between Different Classes of Automotive Steels2025-36-004912/18/2025
The need to reduce vehicle weight without compromising safety drives the use of advanced high-strength steels (AHSS) in the automotive industry. Laser welding is a widely employed technique for joining dissimilar materials due to its high precision and small heat-affected zone (HAZ). However, differences in the chemical composition and thermomechanical properties of the materials can create heterogeneous microstructures in the fusion zone (FZ) and HAZ, directly impacting the mechanical properties of the welded joint. This study aims to evaluate the relationship between microstructure and mechanical properties in laser-welded joints of dissimilar automotive steels. The objective is to understand how microstructural transformations affect weld strength, ductility, and toughness, contributing to process parameter optimization and improved structural performance. Microstructural analysis will be performed using optical microscopy, and mechanical tests, such as tensile testing and
Santos, dos Flávio Nunes, Reis de Faria Neto, dos Antonio, Dias, Erica Ximenes, Martins, Marcelo Sampaio, Santos Pereira, dos Marcelo
Brazing, Nickel Alloy Filler MetalAMS2675J (Current)12/1/2025
This specification covers the requirements for producing brazed joints in parts made of steels, iron alloys, nickel alloys, and cobalt alloys by use of nickel alloy filler metal.
AMS B Finishes Processes and Fluids Committee
Boosting Welding Productivity with the GoFa CobotTBMG-5428112/1/2025
Finland-based Metos Oy, a manufacturer of professional stainless steel kitchen equipment, needed a welding solution that could deliver flawless, pressure-rated welds for small batches of high-spec products, which feature tubular structures and circular shafts that required continuous, precision welding.
Eyes of Robot Operating System for Future Hands2025-28-024611/6/2025
This paper presents a novel approach to automated robot programming and robot integration in manufacturing domain and minimizing the dependency on manual online/offline programming. Traditional industrial robots programming is typically done by online programing via teach pendants or by offline programming tools. This presents a major challenge as it requires skilled professionals and is a time-consuming process. In today’s competitive market, factories need to harness their full potential through smart and adaptive thinking to keep pace with evolving technology, customer demand, and manufacturing processes. This requires ability to manufacture multiple products on the same production line, minimum time for changeovers and implement robotic automation for efficiency enhancement. But each custom automation piece also demands significant human efforts for development and maintenance. By integrating the Robot Operating System (ROS) with vision-based 3D model generation systems, we address
Hepat, Abhijeet
Advanced Manufacturing Processes – Construction Equipment’s2025-28-024311/6/2025
With the global increase in demand for construction equipment, companies face immense pressure to produce more products in a competitive and sustainable way by utilizing advanced manufacturing technologies. Additionally, the need for data analytics and Industry 4.0 is increasing to take better decisions early in the development cycles and during the production phase. Advanced manufacturing processes & adopting Industry 4.0 is the only viable solution to address these challenges. However, the implementation of advanced manufacturing processes in heavy fabrication and construction equipment factories has been slow. A significant challenge is that the products being produced were originally designed for conventional manufacturing processes. When factories are becoming smart and connected through Industry 4.0 solutions, companies must reconsider many established assumptions about advanced manufacturing processes and their benefits. To maximize efficiency gains, improve safety standards
Bhorge, Pankaj, Saseendran, Unnikrishnan, Rodge, Someshwar
Design for Welding Automation for Construction Equipment2025-28-024811/6/2025
Over the past 25 years, the heavy fabrication and construction equipment industry has experienced significant transformation. Driven by a global surge in demand for construction machinery, manufacturers are under increasing pressure to deliver higher volumes within shorter timelines and at competitive costs. This demand surge has been compounded by workforce-related challenges, including a declining interest among the new generation in acquiring traditional manufacturing skills such as welding, heat treatment, and painting. Furthermore, the industry faces difficulties in staffing third-shift operations, which are essential to meet production targets. The adoption of automation technologies in heavy fabrication and construction equipment manufacturing has been gradual and often hindered by legacy product designs that were optimized for conventional manufacturing methods. As the industry transitions toward smart, connected manufacturing environments under the industry 4.0 paradigm, it
Saseendran, Unnikrishnan, Bhorge, Pankaj
Development of Integral Forming for New “NMAX” YECVT Parts Using the Plate Forging Method2025-32-000511/3/2025
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
Printable Heat Shield Formulations Advance Spacecraft ConstructionTBMG-5412011/1/2025
Innovators at NASA Johnson Space Center have developed additively manufactured thermal protection system (AMTPS) comprised of two printable heat shield material formulations. These formulations are directly applied by 3D printer or other robotic extrusion system and bonded to a spacecraft to devise a heat shield suitable for atmospheric entry. This technology could significantly decrease heat shield or thermal protection system (TPS) fabrication cost and time.
Optimization of Arc Welding Parameters for FB590 Hot-Rolled Ferritic-Bainitic Steel with 2.5 mm Thickness05-19-03-001810/31/2025
In this study, the optimization of robotic gas metal arc welding (GMAW) parameters for joining hot-rolled ferritic-bainitic FB590 steel sheets with a thickness of 2.5 mm was investigated. The main objective was to evaluate the effect of wire feed speed and welding speed on the penetration depth, throat thickness, and mechanical performance of the welded joint. A series of welding experiments were carried out with wire feed speeds ranging from 50 cm/min to 100 cm/min and welding speeds ranging from 5 cm/min to 15 cm/min. Tensile and microhardness tests were carried out to evaluate the structural integrity of the welded joints. The results show that increasing the wire feed speed significantly improves the weld penetration and throat thickness, especially at constant welding speeds. The most suitable combination was found to be 70 cm/min wire feed at 8 cm/min travel speed and 100 cm/min wire feed at 12 cm/min and 15 cm/min travel speeds. The microhardness in the heat-affected zone
Babir, Naime, Üzel, Uğur
Aircraft Fire Protection for Helicopter Gas Turbine Powerplant and Related Systems InstallationsAIR1262A (Current)10/21/2025
This document is reissued for application to helicopters. It is primarily intended to apply to the engine or engines, but it shall also apply to fire protection of lines, tanks, combustion heaters, and auxiliary powerplants (APU). Post-crash fire protection is also discussed.
S-12 Powered Lift Propulsion Committee
FITTING END, INTEGRAL CENTERED WELD LIP, DESIGN STANDARDAS4697C (Current)10/21/2025
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Friction Stir Welding Robot Joins the Assembly LineTBMG-5405210/15/2025
Strength Prediction of Self-Piercing Riveted Joints Using Practical Regression and Bayesian Neural Network2025-01-506810/10/2025
Self-piercing riveting (SPR) is a key joining method in multi/thin-material automotive structures, yet accurately predicting the mechanical strength of SPR joints remains challenging due to numerous influencing factors. Empirical engineering equations [1] provide a foundation for estimating lap-shear and cross-tension strength but require several geometric parameters that are often unavailable in the design phase. To address this limitation, we extract and leverage the core physical relationships embedded in these formulas. By reformulating the dependence of joint strength on the yield strength and total thickness of the sheet stack as practical regression models, we enable strength prediction using only commonly available material properties. Furthermore, a Bayesian convolutional neural network (BCNN) model is developed to incorporate additional material features, offering improved prediction accuracy and uncertainty quantification.
Soproni, Istvan, Womack, Darren, Liu, Zongyue, Balaji, Ashwin, Kulange, Deepak
The Power of the Plasma PenTBMG-5397710/1/2025
Plasma pens integrated into production lines provide targeted plasma treatments that reduce failure rates by improving adhesion and bonding in various critical applications.
Investigation of the Effect of Rotation Speed and Post-Weld Heat Treatment on Mechanical Properties and Structure of Friction Stir Welding AA6061 Joints05-19-02-00169/25/2025
This study aims at examining the effect of tool rotational speed on the microstructural and mechanical properties of friction stir welded joints of AA6061 aluminum alloy, both pre- and post-heat treatment. The quality of the joints was assessed initially through tensile, hardness, and charpy impact tests, as well as microscopic observations. During the second stage, solid solution heat treatments were conducted at 535°C, followed by aging on additional specimens welded at identical speeds. The latter underwent hardness tensile tests and microscopic examinations. A comprehensive assessment of the outcomes from various tests validated the influence of metallurgical phenomena, including recrystallization, precipitation, and structural defects on overall resistance. The results showed an improvement in strength, ductility, and impact energy was observed in the case of welding at high rotation speed (1400 rpm). At the same speed, ductility almost doubled after post-weld heat treatment
Bouchelouche, Fatima, Debih, Ali, Ouakdi, Elhadj
Rings, Flash Welded Ferritic and Martensitic Corrosion-Resistant SteelsAMS7493L (Current)9/23/2025
This specification covers flash welded rings made of ferritic and martensitic corrosion-resistant steels.
AMS F Corrosion and Heat Resistant Alloys Committee
Laser Welding for Polymer Tubing: A New Solution for Adhesive- and Additive-Free JoiningTBMG-537789/1/2025
Medical tubing is an essential component of countless healthcare applications, from intravenous (IV) and oxygen lines to catheters and diagnostic equipment. These tubes, often made of clear flexible polymers, must be produced to exacting standards: free of contaminants, strong under pressure, and biocompatible. However, the joining process to connect these tubes can introduce significant manufacturing challenges.
Metallic Materials Properties Development and Standardization (MMPDS) Handbook - 2025 - Volume IIB-993_VOLUME28/13/2025
Volume II publishes the framework for generating and analyzing the data so that material sponsors can generate the right data, knowing how it will be analyzed by the Battelle Memorial Institute. MMPDS-2025 Volume II Process Intensive Materials and Joining Technologies does not currently have any material properties, focusing on additive manufacturing of metallic materials. MMPDS-2025 Volume II focuses on non-conventional processes and will be published each year. Volume I: Conventional Materials and Joint Allowables.
Metallic Materials Properties Development and Standardization (MMPDS) Handbook - 2025 - Volume IB-993_VOLUME18/13/2025
The Metallic Materials Properties Development and Standardization MMPDS-2025 supersedes MMPDS-24 and prior editions of the MMPDS Handbook as well as all editions of MIL-HDBK-5, Metallic Materials and Elements for Aerospace Vehicle Structures Handbook that were maintained by the U.S. Air Force. The last edition, MIL-HDBK-5J was cancelled by the U.S. Air Force in March 2006. This document contains design information on the mechanical and physical properties of metallic materials and joints commonly used in aircraft and aerospace vehicle structures. All information contained in this Handbook has been reviewed and approved using a standardized process. The development and ongoing maintenance process involves certifying agencies, including the FAA, DoD, and NASA, and major material suppliers and material users worldwide. The information and procedures in this Handbook are continuously reviewed and modified or removed as determined to be appropriate. With advances in materials and fastener
Effect of Ce and Cr Additions on the Physical and Mechanical Properties of Materials of Sn-9Zn Solder Alloy05-19-02-00097/22/2025
With rising environmental concerns, developing lead-free solders is crucial for sustainable electronics. Traditional lead-based solders, while effective, pose health and environmental risks, prompt a shift to safer alternatives that retain reliability. Sn-9Zn alloys, when alloyed with elements such as cerium (Ce) and chromium (Cr), show enhanced mechanical and thermal properties suited for modern electronics. This study examines the effects of Ce and Cr, and their combination in Sn-9Zn solder alloy, analyzing improvements in microstructure, thermal, wettability, and hardness properties. Microstructural analysis reveals that Ce and Cr additions refine the alloy’s structure, benefiting performance. Wettability testing shows that Sn-9Zn-0.05Ce achieves the lowest wetting angle, while Sn-9Zn-0.05Ce-0.1Cr displays a balanced angle between Sn-9Zn-0.05Ce and Sn-9Zn-0.1Cr. Differential scanning calorimetry (DSC) results indicate that Sn-9Zn-0.05Ce has the lowest melting temperature, while Sn
Kumar, Niranjan, Maurya, Ambrish
Identification Welding Wire, Tab Marking MethodAMS2816W (Current)7/21/2025
This specification covers procedures for tab marking of bare welding wire to provide positive identification of cut lengths and spools.
AMS B Finishes Processes and Fluids Committee
Brazing, Gold-Nickel Alloy Filler MetalAMS2662A (Current)7/16/2025
This specification covers the engineering requirements for producing brazed joints in parts made of steels, iron alloys, nickel alloys, and cobalt alloys using gold-nickel alloy filler metal.
AMS B Finishes Processes and Fluids Committee
Welded, Flash-Controlled, Low-Carbon Steel Tubing Normalized for Bending, Double Flaring, Beading, Forming, and BrazingJ356_202506 (Current)6/30/2025
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
An Investigation into Friction Stir Surfacing of AA 6061-T6 Alloy on Low-Carbon Steel: Microstructural and Mechanical Analysis05-19-02-00136/30/2025
Friction stir surfacing is an advance surface modification technique, which is functionally evolved from the friction stir welding process. However, the fundamental reason behind the joining of Al/steel is difficult due to the formation of hard and brittle intermetallic compounds (IMC). To address the problem of IMC formation, the current study suggested an alternate production technique with solid-state friction surfacing deposition. In this work, the adhesion mechanism and metallurgical properties of solution-treated AA6061-T6 aluminum alloy cladding over a low-carbon steel IS2062 substrate were investigated. Impact procedural factors (axial frictional force, spindle speed, table traverse speed, consumable rod diameter, and substrate roughness) were examined. Push-off and hardness tests were used to inspect the mechanical properties of cladded samples. 67–77± HV hardness is observed at the interface of the cladded cross-section. A push-off strength of 9 kN was achieved, indicating
Badheka, Kedar Hiteshkumar, Sharma, Daulat Kumar, Badheka, Vishvesh
Increasing Wear Strength and Life Cycle of Tamping Machine Tool by Silicon Carbide Coating for Railway Maintenance05-19-02-00116/19/2025
When a train passes continuously over a section of the track, the track gradually moves away from the intended vertical and horizontal alignment with time and repeated use. Regular maintenance on the track, such as leveling, lifting, lining, and tamping, is necessary to maintain the optimal geometry of the track. Ballast is leveled and squeezed by hydraulic rams in tamping machines. The tamping is a process of ballast packing under railway tracks. In current system a set of tungsten carbide chips are attached either by welding or by coating on tamping tool tip made of EN24 steels. These tungsten carbide chips directly come in contact with the ballasts. After few tamping works, gradually these chips torn out and need to be replaced after certain period. Tungsten carbide is a costly material, therefore this research deals with replacement of tungsten carbide with silicon carbide (easily available cheaper) coating used for tamping tools tip. The study consists of microstructural
Mishra, Mamta, Pandey, Manas, Singh, Shruti, Srivastava, Sanjay, Kumar, Jitendra
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