Browse Topic: Metallurgy

Items (15,985)
Find
Thermomechanical Fatigue Life Prediction of Lamellar Graphite Cast Iron Brake Disks Using Advanced Material Models and Elastic-Plastic Fracture Mechanics2026-01-0816To be published on 09/14/2026
A comprehensive thermomechanical fatigue (TMF) life prediction methodology is developed for cast iron brake disks. The approach employs transient temperature fields as thermal loads in a nonlinear structural finite-element analysis (FEA). To obtain reliable stress and strain histories for cast iron, a time- and temperature-dependent plasticity model is required that captures viscous effects, nonlinear kinematic hardening, and tension–compression asymmetry. For this purpose, a unified elasto-viscoplastic Chaboche constitutive model coupled with damage is developed and implemented as a user material subroutine (UMAT) in the general-purpose FEA software Abaqus by Dassault Systèmes. In addition, a mechanism-based short-crack TMF model is extended to three-dimensional stress states under transient non-proportional loading conditions for TMF life prediction. The material parameters of the constitutive and the damage models are identified for lamellar graphite cast iron using isothermal and
Lee, Heewook, Garcia, Arnoldo, Liu, Yi, Hazime, Radwan, Boughanmi, Heni, Kassir, Abdallah
Evaluation of Structural Service Performance of Low-temperature Modified Asphalt Pavement based on Peavy-Duty traffic Engineering2026-99-1645To be published on 07/24/2026
Relying on the reconstruction project, the low-temperature modified asphalt pavement significantly reduces the construction temperature of the asphalt mixture by 40 °C compared with the traditional asphalt pavement, and improves the road performance of the material. By comparing the two mixture rolling schemes, the compaction effect of scheme 2 is better. For AC-13 mixture, the flexural tensile strength of USP-SBS composite modified asphalt mixture is 0.67 MPa higher than that of SBS modified asphalt mixture, and compared with SBS modified asphalt mixture, the final rut depth of USP-SBS composite modified asphalt mixture is 2.68 mm shallower than that of SBS modified asphalt mixture, and the total deformation rate is 43.8% lower than that of the latter. The post-construction quality evaluation shows that the stability of the low-temperature modified asphalt pavement test section under the bearing capacity and high-temperature-water coupling is better than that of the conventional road
Liu, Chuanfeng, Xu, Ke, Shi, Zheng, Hao, Jidong, Zhao, Liandi, Xianwei, Wang
Enhancement of Tractive Trafficability for a Four-Track Unmanned Amphibious Tracked Vehicle2026-99-05787/10/2026
This study addresses the insufficient tractive trafficability of four-track unmanned amphibious tracked vehicles (UATV) in beach terrain by proposing an optimization strategy based on coordinated suspension height and hitch point adjustment. A mathematical model of vehicle drawbar pull was established to systematically analyze the influence mechanisms of vertical load distribution, suspension adjustment, and hitch point elevation on tractive trafficability. DEM-MBD coupling simulations revealed differentiated traction laws under sandy loam and clay conditions, particularly regarding track overlap effects. Results demonstrate that in sandy loam, rear-axle traversal over front-axle tracks reduces drawbar pull due to soil loosening, whereas track overlap enhances drawbar pull in clay through soil compaction. Nine suspension-hitch configurations were tested, validating optimization strategies: increased front-axle loading (Configuration a) in sandy loam and reduced front-axle loading
Chen, Yaoyao, Gao, Xue, Wang, Wenhao, Xu, Xiaojun
Low-Temperature Internal Heating of Lithium-Ion Cells by Zero-Mean Square-Wave Current Excitation: Thermal Response and Aging Effects2026-01-07537/1/2026
Current lithium-ion batteries should generally only be charged above 0 °C, as charging below this temperature can promote lithium plating and irreversible degradation. However, conventional pack-level heating elements increase system mass and design complexity. In addition, heat is transferred from outside into the cell, causing the temperature inside the cell to rise slowly. This study evaluates internal Joule heating of cylindrical Li-ion cells using a zero-mean square-wave current excitation and quantifies the associated aging impact. LG INR21700-M50L cells were tested at 0 °C, −10 °C, and −20 °C with three excitation frequencies (50 Hz, 1 Hz, 10 mHz) at 5 A amplitude. Each cycle consisted of 30 min heating followed by 60 min cooling; reference capacity-based state of health (SOH) was assessed every 50 cycles up to 400 cycles. A maximum surface temperature rise of 14.3 K was achieved, with larger temperature rise at lower ambient temperature and lower excitation frequency. Capacity
Raiber, Stefan, Allmendinger, Frank, Degler, David, Parschau, Anke
Metal Injection Molded Nickel Based Alloy 718 Parts Hot Isostatically Pressed, Solutioned and AgedAMS5917 (Current)6/19/2026
This specification covers a corrosion and heat-resistant nickel alloy in the form of metal injection molded (MIM) parts.
AMS F Corrosion and Heat Resistant Alloys Committee
Carburizing and Heat Treatment of Carburizing Grade Steel PartsAMS2759/7F (Current)6/15/2026
This specification, in conjunction with the general requirements for steel heat treatment covered in AMS2759, establishes the requirements and procedures for three classes of gas, vacuum, liquid, and low-pressure carburizing (LPC) and related heat treatment of parts fabricated from carburizing-grade steels. Parts made from steels other than those specified in the detail specifications may be heat treated in accordance with the applicable requirements using processing temperatures, times, and other parameters recommended by the material producer. This specification does not cover pack carburizing.
AMS B Finishes Processes and Fluids Committee
Plating, GoldAMS2422G (Current)6/8/2026
This specification covers the requirements for electrodeposited gold plate.
AMS B Finishes Processes and Fluids Committee
Quantifying Life Cycle Environmental Impact of Emerging Aluminum High-Pressure Die Cast (HPDC) Mega-Castings Replacing Stamped Steel Solutions13-07-01-00046/4/2026
Over the last few years, there has been an uptick in the exploration and implementation of aluminum high-pressure die casting (HPDC) mega-castings as replacements for conventional stamped steel parts in vehicles. This trend is expected to increase with common justifications, including claims of reduced costs and lower environmental impacts associated with the replacement of dozens of individual parts with a single casted piece, along with reduced demands on associated tooling and machinery. However, the data and literature to support these claims are limited and at times contradictory, with some studies showing increased costs and energy demands for mega-casting technologies. This study presents the results of a literature review and a gate-to-gate life cycle inventory (LCI) adapted from conventional HPDC aluminum casting unit processes that may be used to quantify potential life cycle global warming potential (GWP), cumulative energy demand (CED), and other environmental impacts of
Sebastian, Brandie, Balzer, Russ
Mitigating Cracking in COP Optics through Annealing and Step-Torquing2026-26-07646/1/2026
Polymeric optical materials such as Cyclo Olefin Polymer (COP) are adopted in aerospace lighting systems due to their excellent optical clarity, dimensional stability, moldability and weight saving advantages over glass. However, their relatively low toughness and the presence of residual molding stress make them prone to crack initiation during mechanical fastening. During its installation, crack formation was consistently observed around self-tapping screw interfaces, raising concerns over reliability, maintainability, and compliance with durability requirements. A structured Design of Experiments (DOE) was performed to identify root causes and evaluate potential mitigation methods. The investigation revealed that residual stresses in the COP material, combined with localized stress concentrations during screw tightening, were the primary drivers of crack initiation. Two complementary process improvements were identified and validated as part of mitigation plan: (i) annealing of the
S, Nikhil, Singh, Abhimanyu Kumar, Katageri, Praveen, SP, Pradeep, Chandra, Praveen
Investigation of Aluminium Alloy Composites Reinforced with Zirconium oxide and Solid Lubricant Attributes for Brake and Clutch Components of Aircrafts2026-26-07526/1/2026
For brake and clutch components of aircraft vehicles which require higher mechanical strength and wear resilient, light-weight aluminium composites were developed infusing solid lubricant. In this study, hybrid composites were developed using powder metallurgy route with aluminum alloy AA356 and various amounts of zirconium oxide (ZrO2) (0, 5, 10, 15, and 20 wt.%) as reinforcements. A solid lubricant hexagonal boron nitride (hBN) at a fixed 5 wt.% is considered. Following the appropriate ASTM guidelines, the specimens were mechanically characterized by measuring their density, porosity, micro-hardness, compression strength, impact strength, and flexural strength, among other properties. The findings showed that the composites' mechanical and physical behaviour were greatly affected by the inclusion of ZrO2. Porosity increased as a result of particle clustering and interfacial voids, while density increased gradually as ceramic content increased. Consistently increasing ZrO2 addition
Senthilkumar, N.
Wear Resilience Characteristics of Silicon Nitride Strengthened AZ31 Magnesium Composite2026-26-07406/1/2026
To develop magnesium matrix composites, ceramic silicon nitride (Si3N4) particles are added to the magnesium (AZ31) matrix at 2 wt.%. The composite is produced via disintegrated melt deposition vacuum-stir-casting procedure. Microstructural studies reveal the presence of Si3N4 particles and their uniform spreading. An L9 orthogonal array, planned using Taguchi’s experimental design, is selected for three wear parameters; axial load (AL), rotational speed (RS), and time duration (TD) with trials as per the G99 standard in the pin-on-disc apparatus to assess the wear resilient of the composite. Experimental results show an increase in axial stress, and wear loss (WL) increases dramatically. Because the area of contact shrinks as RS increases, WL diminishes dramatically. When the AL is low, the friction coefficient (CoF) increases, and when the AL is large, CoF drops. When the RS is increased, CoF decreases. To optimize multiple responses effectively, the TOPSIS (Technique for Order
Senthilkumar, N., Dhinakar Raj, C K
Copper-Beryllium Alloy (Copper Alloy Numbers C17500 and C17510), StripAS81021B (Current)5/20/2026
This specification covers the requirements for the acquisition of two alloys of copper-beryllium alloy strip, having higher electrical conductivity than copper-beryllium alloy strip normally used (see 6.1). All sizes of strip are covered by this specification.
AMS D Nonferrous Alloys Committee
Evaluation of Mechanical Tensile Properties on TIG-Welded AISI 304L Austenitic Stainless Steel Using Principal Component Analysis05-19-04-00275/14/2026
The reliability of welded joints is a vital factor in modern manufacturing, directly affecting product performance and durability. This study investigates methods to enhance the mechanical and metallurgical quality of butt joints in AISI 304L stainless steel welded by the gas tungsten arc (GTA) process. A systematic experimental design was implemented using the Taguchi method with an L9 orthogonal array, considering welding current, gas flow rate, and travel speed as the main parameters. To determine overall weld performance, the joints were characterized by measuring ultimate tensile strength (UTS), yield strength, percentage elongation, and examining their microstructural morphology. An experimental strategy based on the Taguchi approach has been implemented. The welding performance of the material was investigated, and the process parameters were optimized using multiresponse optimization through principal component analysis (PCA), incorporating an orthogonal array design, signal-to
Ghosh, Nabendu, Roy, Angshuman
Optimizing Coil Structural Parameters to Enhance the Sensitivity of Wear Particle Sensor2026-01-50335/14/2026
If wear particles generated during the operation of automobile engines are not monitored in time, they will contaminate the lubricating oil, leading to system failures or even accidents. Therefore, real-time wear particle monitoring is crucial for the stable operation of engines. Among mainstream wear particle monitoring sensors, the three-coil inductive sensor demonstrates significant application potential due to its ability to distinguish wear particle materials and strong resistance to environmental interference. However, its insufficient sensitivity to small-diameter wear particles limits further performance improvement. This paper takes the three-coil inductive wear particle monitoring sensor as the research object. First, a mathematical model of the sensor’s operation is established based on the law of electromagnetic induction, clarifying the relationship between structural parameters (such as channel radius, turns, coil spacing, and length) and the peak induced voltage
Yin, Hao, Zhao, Lijun, Shen, Yitao
Chrome-Free Surface Pretreatment Prior to PaintingAMS3175B (Current)5/7/2026
This specification establishes requirements for chrome-free surface pretreatment materials used for surface preparation of metallic surfaces prior to applying organic coatings.
AMS G8 Aerospace Organic Coatings Committee
Hardness and Conductivity Inspection of Wrought Aluminum Alloy PartsAMS2658E (Current)5/6/2026
This specification establishes hardness and electrical conductivity acceptance criteria for finished or semifinished parts made from wrought aluminum alloys after heat treatment (see 8.6).
AMS D Nonferrous Alloys Committee
How Machina Labs is Reshaping Defense Manufacturing with AI-Driven 7-Axis Robotics26AERP05_015/1/2026
Machina Labs recently closed its latest round of financing with $124 million, enough to develop a facility featuring up to 50 of its RoboCraftsman cells capable of producing thousands of complex structural assemblies for aerospace and defense customers - a list that already includes Lockheed Martin and the U.S. Air Force, among others. Founded in 2019, Machina Labs is a California-based company that seeks to reinvent metal manufacturing with a robot that uses artificial intelligence (AI) to rapidly form and assemble complex military grade structures directly from digital design files. RoboCraftsman is the company's manufacturing robot that leverages its proprietary “RoboForming” process to integrate multiple manufacturing processes - including metal forming, trimming, scanning, and heat treating - into a single containerized machine.
Plating, Nickel-Thallium-Boron or Nickel-Boron, Electroless DepositionAMS2433E (Current)4/25/2026
This specification covers the requirements for an electroless nickel-thallium-boron or nickel-boron deposit on various substrates.
AMS B Finishes Processes and Fluids Committee
Investigation of Metallurgical and Mechanical Behaviors of AA6061-AA2017 Joints Produced by Single- and Double-Pass Friction Stir Welding: Influence of Base Material Position and Post-Weld Shot Peening Technique05-19-04-00264/13/2026
The growing demand for lightweight, high-strength materials in marine and aerospace structures has promoted the use of friction stir welding (FSW) for welding dissimilar aluminum alloys. However, tensile residual stresses and microstructural heterogeneities often degrade weld integrity. This study investigates the combined impact of base material positioning, single- and double-pass FSW, and post-weld shot peening (SP) on the metallurgical and mechanical properties of AA6061–AA2017 joints. Five welding configurations were examined to evaluate how varying base material positions on the advancing and retreating sides affect material flow and mechanical behavior. Post-weld SP effectively presented compressive residual stresses, reduced surface defects, and refined surface grains. The average grain size in the stir zone was reduced from 5.2 μm (single-pass) to 2.0 μm (double-pass U-turn) after SP, confirming significant grain refinement through dynamic recrystallization. Mechanical testing
Nukathoti, Raja Sekhar, Battina, N. Malleswara Rao, Vanthala, Varaha Siva Prasad, Chirala, Hari Krishna, Maloth, Balu
Steel, Corrosion-Resistant, Investment Castings, 16Cr - 1.9Ni - 0.08N (431), As CastAMS5353G (Current)4/12/2026
This specification covers a corrosion-resistant steel in the form of investment castings.
AMS F Corrosion and Heat Resistant Alloys Committee
Aluminum Alloy, Sheet and Plate, Alclad 4.4Cu - 1.5Mg - 0.60Mn (2024 -T361 Sheet/Plate with 1½% Alclad) Solution Heat Treated, 6% Cold Worked and Naturally AgedAMS4194F (Current)4/8/2026
This specification covers an aluminum alloy in the form of sheet and plate, alclad both sides, supplied in the -T361 temper.
AMS D Nonferrous Alloys Committee
Strain-Based Fracture Assessment of Tailor Welded Blanks under Complex Loading Conditions2026-01-02314/7/2026
Tailor Welded Blanks are critical for automotive lightweighting yet prone to premature failure due to differential thickness and strength across the weld. This study utilized digital image correlation (DIC) to analyze the maximum in-plane principal Hencky strain (E₁max) and axial strain (εₐₓₐₗ) of TWBs under complex loading conditions, including biaxial and plane-strain states. Twelve distinct material stack-ups were tested to evaluate the impact of material difference on formability. Results indicated that differential properties significantly altered strain distribution, often forcing localization onto the thinner or softer sheet. While UHSS welds provided high load capacity with limited ductility, combinations using HSLA or IF substrates were susceptible to early localization and unstable fracture. Comparative heatmaps illustrate strain evolution across all samples, providing spatial insights beyond conventional force–displacement analysis. Metallurgical characterization confirmed a
Aminzadeh, Ahmad, Sheng, ZiQiang, Huang, Lu, McCarty, Eric, Biro, Elliot
Machine Learning-Based Prediction of Tensile Properties in Cast Stainless Steel Influenced by Chemical Composition Variation2026-01-02374/7/2026
In the category of cast stainless steels, there are several variants per different level of addition of chromium, vanadium along with some minor elements, such as molybdenum, niobium, tungsten to meet the requirement of corrosion and oxidation resistance. However, the influence of chemical composition variations on the mechanical properties of cast SS continues to lack a clear understanding. In the present study, via machine learning, the effects of each element on the tensile properties of the selected cast stainless steel are studied. The machine learning model is then used to predict how variations in elements affect tensile behavior, with the predictions validated through physical testing.
Mishra, Neelam, Biswas, Surjayan, V S, Rajamanickam, Aluru, Phani, Liu, Yi, Akbari, Meysam, Coryell, Jason
Tensile and Fatigue Behavior of High Pressure Die Cast AE44 Magnesium Alloy at Elevated Temperatures2026-01-02344/7/2026
Tensile and cyclic behavior of high pressure die cast AE44 magnesium alloy have been studied at room temperature and elevated temperatures up to 350°C. Anelastic behavior has been found in both tensile and cyclic loading at the temperature below 200°C. With increasing temperature, the anelasticity disappears, and tensile and cyclic behaviors become like other engineering materials, such as steels and aluminum alloys, i.e. the total strain contains only elastic strain and plastic strain. A method to determine the yield strength at 0.2% plastic strain (σ0.2) is proposed. By using the proposed method, the yield strength σ0.2 is found to be higher than that determined using the traditional method, which is more suitable to the materials that do not exhibit anelasticity. It is believed that the anelasticity is closely related to twinning in Mg alloy, which disappears at elevated temperatures.
Liu, Yi, Yang, Wenying, Coryell, Jason
Simulation-Based Evaluation of Lithium-Ion Batteries Manufacturing Performance2026-01-70052/27/2026
Lithium-ion batteries (LIBs) have become indispensable components in diverse energy applications driven by their high energy density, long cycle life, and low self-discharge. These excellent characteristics are directly influenced by their manufacturing processes, where variations in battery design and processing parameters will lead to significant differences in performance. Therefore, reliable and efficient evaluation of battery performance across manufacturing processes is essential for quality assurance and process improvement. Traditional methods rely on formation cycling and associated electrochemical tests, which are time and cost intensive. Different from them, a simulation-based approach for manufacturing performance evaluation is proposed in this study. The method employs the pseudo two dimensions (P2D) electrochemical model within the PyBaMM framework, where model parameters such as electrode type, electrode size, and particle size are derived from manufacturing data and
Yan, Yifei, Meng, Jinhao, Song, Zhengxiang, Zhang, Shirui, Pan, Yuhao, Yang, Peihao, Peng, Jichang
Electrochemical–Thermal Coupled Modeling and Optimization of Fast Charging for Lithium-Ion Batteries2026-01-70112/27/2026
This study systematically investigates methods to enhance the fast-charging capability of lithium-ion batteries through advanced simulation. The electrochemical reaction mechanism, heat generation mechanism, and lithium plating mechanism are analyzed in detail, and an electrochemical–thermal coupled model incorporating a lithium plating sub-model is established. A hybrid parameter identification strategy, combining random search, grid search, and manual adjustment, is employed to calibrate the model across different operating conditions, thereby improving its accuracy in reproducing real battery behavior. Lithium plating is selected as the primary indicator to evaluate fast-charging performance. Based on simulation results, the effects of both operational parameters and structural parameters on lithium plating are thoroughly analyzed. The results indicate that lower charging rates, elevated charging temperatures, higher electrode porosity, and reduced tortuosity are favorable for
Zhao, Peiqiang, Zhan, Wenwei, Qi, Ji, Yi, Yong
Tools for Peening Intensity Determination and VerificationJ442_202602 (Current)2/17/2026
This SAE Recommended Practice defines requirements for equipment and supplies to be used in measuring shot peening intensity and other surface enhancement processes. It is intended as a guide toward standard practice and is subject to change to keep pace with experience and technical advances. Guidelines for use of these items can be found in SAE J443 and SAE J2597.
Surface Enhancement Committee
Blackening Solution for Steel Touch-Up MethodAMS2484D (Current)2/16/2026
This specification covers the requirements for an inorganic blackening solution for steel, applied at room temperature.
AMS B Finishes Processes and Fluids Committee
Aluminum Alloy, Sheet and Plate, Alclad 4.4Cu - 1.5Mg - 0.60Mn (Alclad 2024, -T361 Sheet and Plate) Solution Heat Treated, 6% Cold Worked, and Naturally AgedAMS4466C (Current)2/13/2026
This specification covers an aluminum alloy in the form of alclad sheet and plate 0.020 to 0.500 inch (0.508 to 12.70 mm), inclusive, in thickness, supplied in the -T361 temper (see 8.5).
AMS D Nonferrous Alloys Committee
Genetic Algorithm Based Optimization of Chaboche Kinematic Hardening Parameters along with the Validation of FE Model through Characterized Crack Initiation2026-28-00862/12/2026
In the context of electro-mobility for commercial vehicles, the failure analysis of a connector panel in a DCDC converter is crucial, particularly regarding crack initiation at the interface of busbar and plastic component. This analysis requires a thorough understanding of thermo-mechanical behavior under thermal cyclic loads, necessitating kinematic hardening material modeling to account for the Bauschinger effect. As low cycle fatigue (LCF) test data is not available for glass fiber reinforced polyamide based thermoplastic composite (PA66GF), we have adopted a novel approach of determining non-linear Chaboche Non-Linear Kinematic Hardening (NLK) model parameters from monotonic uniaxial temperature dependent tensile test data of PA66GF. In this proposed work a detailed discussion has been presented on manual calibration and Genetic Algorithm (GA) based optimization of Chaboche parameters. Due to lack of fiber orientation dependent test data for PA66GF, here von Mises yield criteria
Basu, Parichay, Srinivasappa, Naveen
Aluminum Alloy Hand Forgings and Rolled Rings, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061-T652), Solution Heat Treated, Stress Relief Compressed, and Precipitation Heat TreatedAMS4248E (Current)2/6/2026
This specification covers an aluminum alloy in the form of hand forgings up to 8 inches (203 mm), inclusive, in nominal thickness and a cross-sectional area not over 256 square inches (1652 cm2) and rolled rings up to 3.5 inches (89 mm), inclusive, in nominal thickness and with an OD to wall thickness ratio of 10:1 or greater (see 8.6).
AMS D Nonferrous Alloys Committee
Direct Deposition of Nickel Abrasion Guards on to Carbon Filled Composite Rotor Blade StructuresSM-2026-VLADA-51991/27/2026
Composite materials have become widely adopted in commercial aviation, as aerospace manufacturers look to use them to drive weight reduction and improved fuel efficiency in new aircraft designs. In the case of aircraft rotary blades, the poor wear properties of these materials have necessitated the development of metal leading edge guards that can provide critical protection against erosion and impact damage during flight. Electroforming has been a leading process for the manufacture of these protective guards, with nickel parts providing excellent wear resistance that significantly extends the service life of the rotary blade assembly. Currently there has not been a focus on utilizing direct electrodeposition of metal on to carbon filled epoxy composite structures, as traditional plating-on-plastics approaches require considerable effort in surface preparation and normally do not provide adequate adhesion to the underlying structure. Alpha Metalcraft Group has been working in
Cazzaniga, Luigi
Plating, Silver, Copper Strike, Low BakeAMS2412M (Current)1/26/2026
This specification covers the requirements for silver deposited on metal parts with a copper strike between the basis metal and the silver deposit.
AMS B Finishes Processes and Fluids Committee
Plating, CadmiumAMS2400Z (Current)1/22/2026
This specification covers the requirements for electrodeposited cadmium on metal parts.
AMS B Finishes Processes and Fluids Committee
Multi-Material Front Structures: A Pathway to Safer and More Sustainable Vehicle Design2026-26-04561/16/2026
Frontal crash structures play a vital role in occupant safety, but traditional designs often involve a trade-off between structural strength and weight efficiency. In the pursuit of safer and more sustainable mobility, this study explores a physics-based methodology that leverages the principle of dynamic equilibrium to guide the integration of dissimilar materials in front-end vehicle structures. Specifically, examined a novel configuration wherein aluminum High-pressure die cast (single HPDC part) is introduced which covers swan neck region as well as the base of the front longitudinal member, while retaining steel in the frontal crush zone. This arrangement aims to redistribute crash loads and control deformation mechanisms, enabling improved energy absorption without compromising structural integrity. To evaluate the proposed strategy, a series of detailed finite element simulations were conducted using LS-DYNA, a widely adopted tool for vehicle crash analysis. The results reveal
Revanth, Goshika, Bhagat, Milind, Joshi, Vikas, Mankhair, Abhijit, Sudarshan, B.Sudarshan, Kollipara, Jahanavi
Hydrogen Embrittlement in Galvanized High Carbon Steel Components of Automotive Seat Slider Assembly2026-26-03021/16/2026
This research paper investigates the failure of an isolator clip used in the seat slider assembly, which guides and restricts the sliding motion of the tooth bracket within the seat. The component is made of C80 high-carbon spring steel, known for its high strength. According to the manufacturing process details, zinc plating was applied to the component for corrosion protection, as confirmed by EDS analysis. A fractographic examination of the failed part revealed a brittle, intergranular fracture morphology with visible cracks. Certain areas also exhibited micro-void coalescence, indicating a dimpled fracture surface. The primary failure mode was intergranular (IG) fracture. The delayed fracture was attributed to intergranular fracture mechanisms, micro-void coalescence, and the high strength of the steel, which made the component susceptible to hydrogen embrittlement. Hydrogen embrittlement occurs when hydrogen atoms become trapped along the grain boundaries, where they form hydrogen
Saindane, Mehul Kishor, Bali, Shirish
Evaluation of Shear Trim Edge in HSLA Steel for Automotive Application2026-26-02861/16/2026
Quality of the Shear Trimmed edge of HSLA 550 steels is significantly affected by process variations such as Shear Trimming Clearance, trim tolerance, burr height and clamping force. All these parameters largely influence the characteristics of the Shear Affected Zone, a region on sheet metal where it undergoes deformation during the trimming process. The Shear Affected Zone is predominantly vulnerable to failure due to work hardening and the effects of strain rate, induced by the tonnage during the trimming operation. To assess the edge ductility of these materials, Tensile, Fatigue Strength, Die Punch Clearance, Roughness and Hardness Tests are carried out. These tests are crucial for applications that demand high formability and resistance to edge failure. Virtual simulation of edge trimming operation using elastoplastic material models in LS-Dyna have been performed to gain insights into burr formation and damage evolution during shearing. These simulations act as a precursor to
Thota, Badri Vishal, Kashyap, Amit, Bhuvangiri, Jaydev
Hypoid Gear Performance Redefined: Addressing Scoring & Whine Noise Concerns2026-26-00781/16/2026
Rear drive vehicles transfer power to the rear wheels through the Gear Carrier Assembly, which is fit at the central section of the Rear Axle. The Gear Carrier Assembly includes hypoid ring and pinion gears, set at the heart of the system. However, one of the common issues with hypoid gears is gear scoring and whine noise, both of which can seriously affect durability and reduce the overall performance of a vehicle. In this study, the focus is on design changes as well as process improvements to address these problems and at the same time improve gear reliability. On the design side, changes such as refining the macro geometry, upgrading materials, and modifying the heat treatment cycle were carried out. These helped in improving properties like contact stress resistance, bending and impact strength, and also reduced motion transmission error (MTE). From the process point of view, careful control over carburizing, hardening, and quenching temperatures, along with adjustments in
Praveen, Abhinav, Deshpande, Praveen, Jain, Saurabh Kumar, Parmar, Mayur, Karle, Nilesh, Kanagaraj, Pothiraj, Pagar, Pawan
Incorporation of Strain Hardening and Sheet Thinning Effects during Forming Process for an Accurate Prediction of Buckling Loads on Sheet Metal Axle Parts2026-26-03911/16/2026
In the automotive industry, during the early phase of development, numerical prediction of strength and durability of chassis parts become crucial as these predictions help in design optimization, selecting the appropriate material and identifying potential issues before physical prototypes are built. One of the crucial simulation requirements is the prediction of accurate load carrying capacity or bucking load of axle links. When it comes to the sheet metal axle links there is a deviation in the hardware test and CAE results for load carrying capacity due to the non-integration of forming effects in the numerical simulation, resulting in overdesign of parts, increased costs and development time. This study aims to address these challenges by integrating forming effects experienced by the part during forming process into static strength simulations. These effects include plastic straining, which contributes to material strain hardening and local thickness changes that lead to thinning
R B, Govind, Selvaraj, Nirmal Velgin
Non-Metallic Inclusions in Carburizing Steels as a Contributory Factor for the Formation of Carbide Net2026-26-02901/16/2026
The article deals with the issue of identifying structural defects that contribute to the formation of a carbide net during thermochemical treatment of steel parts, which negatively affects the mechanical properties complex of finished products. Based on the available data, a theory has been put forward regarding the influence of the present non-metallic inclusions in the carburizing steels structure on carbide formation process in the hardened layer. As an experimentally the samples have been produced from the varying chemical composition alloy structure carburized steel (0.17-0.23 % C, 0.17-0.37 % Si, 0.80-1.10 % Mn, 1.00-1.30 % Cr, 0.03-0.09 % Ti). During microstructure analysis of the samples it has been establish that non-metallic inclusions, in particular sulfides, contribute to the formation of carbides and carbide net in steel due to their high chemical activity with carbon. Thus, contamination of the metal of carburizing steels with non-metallic inclusions is not only a defect
Runova, Iuliia, Chatkina, Mariia, Musienko, Aleksandr
Effect of Flow Forming Process on the Mechanical Properties and Microstructure of GDC & LPDC Cast Aluminium Alloy Wheels2026-26-02981/16/2026
Aluminum alloy wheels have become the preferred choice over steel wheels due to their lightweight nature, enhanced aesthetics, and contribution to improved fuel efficiency. Traditionally, these wheels are manufactured using methods such as Gravity Die Casting (GDC) [1] or Low Pressure Die Casting (LPDC) [2]. As vehicle dynamics engineers continue to increase tire sizes to optimize handling performance, the corresponding increase in wheel rim size and weight poses a challenge for maintaining low unsprung mass, which is critical for ride quality. To address this, weight reduction has become a priority. Flow forming [3,4], an advanced wheel rim production technique, which offers a solution for reducing rim weight. This process employs high-pressure rollers to shape a metal disc into a wheel, specifically deforming the rim section while leaving the spoke and hub regions unaffected. By decreasing rim thickness, flow forming not only enhances strength and durability but also reduces overall
Singh, Ram Krishnan, Medaboyina, HarshaVardhan, G K, Balaji, Gopalan, Vijaysankar, Sundaram, Raghupathi, Paua, Ketan
Optimization of Global and Local Formability Properties through Nb Microalloying2026-26-03031/16/2026
David Martin, CBMM Asia Bernardo Barile, CBMM Europe BV Caio Pisano, CBMM Europe BV Automotive high strength steels have specific microstructure-dependent forming characteristics. Global formability is generally associated with high uniform strain values which imply good drawability and stretch forming properties driven by pronounced work hardening. Local formability on the other hand is often measured by various fracture strain values—generally higher in single phase steels. In this respect, the so-called ‘local/global formability map’ concept has been established not only to provide a comprehensive methodology to characterize existing automotive steels but also to enable improvement strategies toward more balanced forming characteristics. Niobium (Nb) microalloying is a powerful tool to achieve both property improvement in general and property balance in particular. More than two decades of research has demonstrated that Nb-induced microstructural optimization is applicable to HSLA
Barile, Bernardo
Predictive Analysis and Risk Management of Nickel-Plated Aluminum Automotive Parts Exposed to Harsh Environmental Conditions2026-26-03051/16/2026
Aluminium is widely used across various industries due to its lightweight properties, high strength-to-weight ratio, and cost-effectiveness. However, its susceptibility to corrosion, particularly in harsh environmental conditions, presents challenges to its long-term durability and performance. To mitigate these issues, nickel plating was applied as a protective measure, creating a barrier to minimize aluminium’s direct exposure to corrosive environments and enhance its resistance to degradation. In this study, nickel-plated aluminium was subjected to controlled corrosion testing under simulated real-world conditions, including humidity, saline atmospheres. The primary objective was to evaluate the effectiveness and longevity of nickel plating as a corrosion prevention method. Periodic observations and measurements were conducted to monitor material changes, such as surface degradation, corrosion pattern and corrosion increasing rate. The findings highlight the critical role of plating
Narain, Aditya, Venugopal, Sivakumar, Gopalan, Vijaysankar, Varatharajan, Senthilkumaran
Comparative Study of ADC12, A356, and AlSi10Mg Alloys in Sand Casting of EV Battery Housing2026-26-02961/16/2026
This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines
Subramani, Rajesh, Singh, Gajendra, Doddamani, Mrityunjay
Optimization of the Hood Ro-dip CED Process Through Strategic Support Rod Placement at Multiple Locations for Enhanced Hood Gap and Flushness Control in Automotive Manufacturing2026-26-04861/16/2026
The Ro-dip Cathodic Electrodeposition (CED) process is new technology used by automotive manufacturers for higher quality corrosion protection in new generation automobiles. This process involves multiple 360-degree rotation of automotive body-in-white (BIW) which exert higher hydrostatic pressure and drag forces on large surface panels of BIW like hood. For maintaining consistent gaps and flushness control at vehicle level, it is important to safeguard the dimensional stability of light weight (crash performance sensitive) steel hood panel while undergoing through this CED process. This study investigates the enhancement of hood structure supports through strategic optimization of support rod placement and quantity within the Ro-dip CED paint shop system. This Paper underscore the importance of tailored fixture design in the Ro-dip CED process, offering a scalable solution for automotive manufacturers aiming to improve quality while reducing costs associated with dimensional
Tile, Vikrant, Unadkat, Siddharth, Askari, Hasan, Jadhav, Devidas
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
Advancement in Analytical Characterization of NBR: Py-GC-MS as an Alternative to NMR for Acrylonitrile Quantification2026-26-05461/16/2026
Nitrile Butadiene Rubber (NBR), known for its superior resistance to hydrocarbon oil, low gas permeability, and excellent thermal stability, finds extensive use in seals, O-rings, conveyor belts etc. Importantly, these performance attributes are chiefly governed by acrylonitrile content in NBR. Analytical characterization of raw NBR is relatively straightforward using conventional techniques such as elemental analysis (CHNS) and liquid state 13C NMR. In contrast, the analysis of vulcanized NBR presents considerable challenges due to its crosslinked structure, which renders it insoluble in most organic and inorganic solvents, thereby restricting direct molecular-level analysis. While solid-state 13C NMR is an established technique for structural characterization in rubber vulcanizates, its high-cost curbs routine industrial analysis. In this study, Pyrolysis-Gas Chromatography-Mass Spectrometry (Py-GC-MS) technique has been explored as a robust, precise, cost-effective alternative
Samanta, Rajyasree, Ghosh, Debojit, Anjana, Kanhaiya, Sen, Amit, Guria, Biswanath, Chanda, Jagannath, Samui, Barun, Ghosh, Prasenjit, Mukhopadhyay, Rabindra
Design and Application of Large-Segment Cable Hanging Baskets for Long-Span High-Speed Railway Cable-Stayed Bridges2025-99-021912/23/2025
With the advancement of cable-stayed bridge construction technology, the application of long-span concrete girder cable-stayed bridge is gradually extensive, making the study of construction technology and equipment for concrete main girders increasingly important. The cable hanging basket, a crucial piece of equipment for cable-stayed bridge construction, maximizes the cable’s bearing capacity, improves construction efficiency, and ensures safety and stability during construction. However, due to the varying structural designs and construction environments, the cable hanging basket must be specifically tailored for different cases. The Hanjiang Bridge on the Xi’an-Shijiazhuang High-speed Railway is China’s first steel-truss-reinforced PC box-girder cable-stayed bridge, with a main span of 420 meters. If conventional diamond-shaped hanging baskets are used for suspended casting of small sections, the construction period will not meet the construction requirements of this bridge. To
Li, Jian
Development of a Localized Heat Treatment Route for Stamped Automotive Parts2025-36-008912/18/2025
The increasing demand for sustainable and space-efficient manufacturing solutions in the automotive industry has driven the search for alternative processes to conventional hot stamping. This study proposes a novel localized heat treatment technique based on Joule heating, aiming to reduce the physical footprint of production equipment, simplify the thermal processing of structural components, and minimize the carbon footprint of the process. The method consists of cold stamping followed by localized austenitization of 22MnB5 steel using electrically powered copper electrodes, eliminating the need for large-scale gas-fired furnaces. The process is particularly advantageous in the Brazilian context, where the electric energy matrix is predominantly hydroelectric, contributing to lower CO2 emissions. Experimental trials were conducted using a Gleeble® thermomechanical simulator to optimize thermal cycle parameters (heating rate, austenitization temperature, and soaking time) ensuring the
Santana, Jessica, Curti, Gustavo, Lima, Tiago, Sarmento, Matheus, Callegari, Bruna, Folle, Luis
Anodic Treatment of Aluminum Alloys, Chromic Acid ProcessAMS2470R (Current)12/15/2025
This specification establishes the requirements for anodic coatings on aluminum alloys.
AMS B Finishes Processes and Fluids Committee
Items per page:
1 – 50 of 15985