Browse Topic: Coatings, colorants, and finishes

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Paint Dip-in and Drain-out Analysis for Off-road Applications Using Low Fidelity Versatile Multi-Phase Simulation Practices2025-28-024411/06/2025
In complex manufacturing processes, reliable simulation tools are essential to supplement expensive prototyping and physical testing, optimizing the design stage efficiently. The manufacturing industry seeks solutions for e-coating, which involves optimizing design parameters like tank dimensions, part trajectory, line speed, and geometrical details. New generation CFD tools, such as Creo Flow Analysis (CFA), offer high accuracy, efficient workflows, and short computational times. The goal is to gain insights into how design parameters affect the process and optimize them. CFA provides powerful Volume of Fraction (VOF) multiphase simulation techniques along with body motions in a user-friendly process, enabling quick verification of painting processes or part designs. Surface coating protects industrial products from corrosion and other environmental influences. Electrophoretic coating (e-coating) is a surface engineering process used to coat metallic components. The paint deposition
Rao, Pooja Dhaval, Tirumala, Bhaskar, Soni, Tanushree
Transformative Deep Learning for Image Colorization with Machine Learning-Based Classification2025-28-031711/06/2025
Imagine a user opening a technical manual, eager to troubleshoot an issue, only to find a mix of stark black-and-white illustrations alongside a few color images. This inconsistency not only detracts from the user experience but also complicates understanding. For technicians relying on these documents, grayscale graphics hinder quick interpretation of diagrams, extending diagnostics time and impacting overall productivity. Producing high-quality color graphics typically requires significant investment in time and resources, often necessitating a dedicated graphics team. Our innovative pipeline addresses this challenge by automating the colorization and classification of existing grayscale graphics. This approach delivers consistent, visually engaging content without the extensive investment in specialized teams, enhancing the visual appeal of materials and streamlining the diagnostic process for technicians. With clearer, more vibrant graphics, technicians can complete tasks more
Khalid, Maaz, Akarte, Anurag, Kale, Aniket, Rajmane, Gayatri, Nalawade, Komal
Influence of Laser Sintered Process Parameters on Crystalline Characteristics and Mechanical Properties of AlSi10Mg Alloy05-19-03-001911/03/2025
The present study examines the influence of process parameters on the effect of strength and crystalline properties of AlSi10Mg alloy with laser sintered process. A detailed work was carried out with the effects of varying the laser power, scan speed, and hatch distance on crystalline structure, hardness, and surface roughness. From the analysis, the improved surface quality and mechanical performance were achieved with a scan speed of 1200 mm/s, a laser power of 370 W, and a hatch distance of 0.1 mm. An increase in hardness, improved surface finish, and reduced porosity was observed with decreased hatch distance. However, the balanced results were obtained for scanning speed of 1200 mm/s and laser power of 370 W. The ideal processing conditions decreased the crystalline size, increasing the overall material strength, when crystalline analysis was carried out. The higher scanning speeds supported improved grain refinement and heat diffusion, with the poor hardness value. With the lower
Shailesh Rao, A.
Research on Reflective Characteristics of Road Tunnel Pavement and Low Carbon Energy Saving Technology2025-99-001010/17/2025
Highway tunnel lighting has a key impact on traffic safety and lowcarbon energy saving. Under the same lighting conditions, the brightness and uniformity of the road surface are closely related to the reflection characteristics of the road surface. In this paper, firstly, the brightness of asphalt concrete specimens made of different materials was tested by indoor experiments, and the reflective parameters of asphalt concrete of different colors were compared, and then the images of colored pavement of different colors were collected at the tunnel site, and the brightness and uniformity indexes of the colored pavement and the conventional asphalt pavement were analyzed and compared by using graphic image analysis technology. The results show that when the lighting conditions are the same, the luminance of yellow asphalt concrete is about 2.3 times that of black asphalt concrete, and the luminance of red asphalt concrete is about 1.5 times that of black asphalt concrete, and the use of
Si, Jialai, Wang, Zijian, Wang, Luhai, Ma, Fei, Han, Lulu, Zhang, Zhongbin
A Microstructural Comparison of NiCoCrAlY Superalloy Coatings Manufactured by Combustion Flame Spray and High-Velocity Oxygen Fuel Processes05-19-03-001710/15/2025
NiCoCrAlY powders were thermally sprayed by combustion flame spray (CFS) and high-velocity oxygen fuel (HVOF) processes on IN 718 alloy substrates. Experimental parameters were fixed to manufacture coatings with a thickness about 200 μm. Microscopy and X-ray diffraction analyses were performed to reveal microstructural characteristics of both developed CFS and HVOF coatings, and it was observed that they were formed by a lamellar morphology composed of β and γ phases. The analyses also revealed lower porosity in the coatings produced by HVOF process while was compared with CFS process. While a microstructure composed of like-deformed powder was developed in HVOF process, in the case of CFS a building layer-by-layer was characteristic. Vickers hardness tests were also performed, and it was found that coating developed by HVOF process showed quite higher hardness values compared with those measured on the coatings developed with the CFS process, nonetheless this difference was small
Juarez-Lopez, Fernando, Mendoza, Melquisedec Vicente, Meléndez, Rubén Cuamatzi, Ramírez, Ángel de Jesús Morales
Study on Oil Film Thickness of Piston Skirt Pattern Coating in a Commercial Vehicle Diesel Engine2025-01-039710/07/2025
In recent years, there has been a trend towards lower engine speeds and downsizing of diesel engines to improve fuel efficiency. This has the advantage of reducing frictional losses in the hydrodynamic lubrication condition but causes severe lubrication in the mixed lubrication condition. In order to reduce friction losses without the risk of abnormal wear or seizure, pattern coatings of the piston skirt area have been proposed. In this study, the oil film thickness between piston and cylinder was measured to investigate the effect of pattern coating on the oil film thickness. The oil film thickness between the piston and cylinder were measured by the laser-induced fluorescence method using the optical fibers embedded in the cylinder. The oil film thickness on the piston skirt was successfully measured under the engine operating conditions for the medium duty Direct Injection (DI) diesel engine. The oil film thickness for the pattern coatings was compared with that for the solid
Tanimoto, Keisuke, Ito, Akemi, Sumoto, Masayuki
CRIMPING TOOL, TYPE II, WIRE HEATLESS TERMINATION, HAND ACTUATED, WIRE SIZES 26-12AS22520/44A (Current)10/03/2025
AE-8C2 Terminating Devices and Tooling Committee
FERRULES, OUTER, INSULATED, SHIELD TERMINATING, TYPE II TWO-PIECE, CLASS I, FOR SHIELDED CABLEAS18121B (Current)10/03/2025
AE-8C2 Terminating Devices and Tooling Committee
Guide for Identification of Terminal Lugs in Electrical Wiring Interconnect Systems (EWIS)ARP6807A (Current)10/02/2025
The intent of the SAE Aerospace Recommended Practice (ARP) is to provide a process for users to identify the part number of AS7928 terminal lugs installed in civilian or military applications, although it can also be used to identify terminals that have been stored incorrectly. This ARP is subject to change to keep pace with experience and technical advances of AS7928 terminals. A current set of tables are provided to list and identify current AS7928 terminal lug configurations per the associated specification detail sheet and terminal lug configuration. Specific configuration details, graphic, size, and marking information for each individual terminal lug is provided to assist the product user with accurate selection for replacement or identification.
AE-8C2 Terminating Devices and Tooling Committee
Aircraft Oxygen System Lines, Fabrication, Test, and InstallationARP1532B (Historical)09/18/2025
This SAE Aerospace Recommended Practice (ARP) covers procedures or methods to be used for fabricating, handling, testing, and installation of oxygen lines in an aircraft oxygen system.
A-10 Aircraft Oxygen Equipment Committee
Effects of Moisture Behavior on Corrosion Stiction in Friction Materials2025-01-033309/15/2025
This study investigates the correlation between moisture behavior and corrosion stiction mechanisms in NAO friction materials. While previous studies on corrosion stiction have primarily focused on electrochemical approaches, this study aims to elucidate the mechanism by examining moisture behavior within the friction material. Although recent research has investigated changes in pad properties in humid environments, most studies have primarily focused on variations in pad stiffness and the friction coefficient. To date, no studies have investigated the behavior of moisture within pads using Fick’s Second Law and its impact on corrosion stiction. In this study, Fick’s Second Law was applied to model moisture behavior in friction materials. The diffusion coefficient and maximum moisture content were quantified, revealing that moisture behavior in the friction material can be divided into two distinct stages: one following Fick’s Second Law and the other not. For NAO friction materials
Choi, Nakcheon, Ju, Joungsu, Youn, Deokki
Thermal Stress Reduction in Diesel Engine Pistons Using Semitransparent Ceramic Coatings: A 3D Numerical Study with OpenFOAM2025-24-000309/07/2025
This research focuses on the thermal analysis of internal combustion engine pistons, evaluating the effects of high-temperature exposure during operation. A three-dimensional numerical study is conducted using OpenFOAM, modifying the software’s governing equations to analyze temperature distribution in different piston geometries. The study aims to assess the spatial temperature variation within the entire volume of the piston, providing a detailed understanding of heat transfer mechanisms. A multilayer approach is implemented, considering various configurations of ceramic coatings with distinct thermal and optical properties. The investigation incorporates an internal heat source model, where the heat absorption characteristics of the coating material influence the thermal behavior of the system. By evaluating aluminum- and titanium-based ceramic coatings, the study examines how semitransparency and heat radiation absorbance affect heat accumulation and transfer. The results highlight
Gutierrez, Marcos, Taco, Diana, Bösenhofer, Markus
FibreCoat's New Radar-Absorbing ‘Stealth’ Fiber Reinforced Composites for Spacecraft, Aircraft and Tanks25AERP09_0609/01/2025
FibreCoat, the German materials startup, has developed a groundbreaking fiber reinforced composite that is capable of making aircraft, tanks and spacecraft invisible to radar surveillance. The company was officially founded in Aachen, Germany, in 2020, however its core founding team first began developing new approaches to the use of materials that make commercial and military vehicles invisible to radar as back as 2014. FibreCoat is known for inventing a novel technology to coat metals and plastics onto fibers, thus combining the properties of the fibers and the coating material, during the fiber-spinning process.
Positioning Wafers with Micrometer Precision for PECVD CoatingTBMG-5370909/01/2025
Thin Film Sensor for Ultra High-Temp MeasurementTBMG-5371809/01/2025
Innovators at NASA Johnson Space Center have developed a thin film sensor that measures temperatures up to 1200 °F, and whose prototype successor may achieve measurements up to ~3000 °F — which was the surface temperature of the Space Shuttle during its atmospheric reentry.
Drywall Finishing Robots Accelerate Construction SchedulesTBMG-5353308/01/2025
San Francisco startup Canvas has developed a robotic system handling one of the most labor-intensive trades in construction: drywall finishing. Leveraging robotic arms from Universal Robots, Canvas has built a machine that reduces the usual five to seven days of spraying and sanding the drywall to just around two days for both Level 4 and Level 5 finishes.
Smoothing Over Rough Edges in BatteriesTBMG-5352908/01/2025
Battery performance suffers over time, like when a phone needs to be charged more frequently after years of use. A thin film that forms on the metal anode when the battery is charging and discharging plays a part in that issue. This film has benefits, but its roughness gradually wears the battery down.
New Laser Technique Revolutionizes Ultra-High Ceramic Manufacturing for Spacecraft25AERP08_0708/01/2025
Researchers have demonstrated a new technique that uses lasers to create ceramics that can withstand ultra-high temperatures, with applications ranging from nuclear power technologies to spacecraft and jet exhaust systems. North Carolina State University, Raleigh, NC A new technique that leverages the concept of sintering, can be used to create ceramic coatings, tiles or complex three-dimensional structures, which allows for increased versatility when engineering new devices and technologies. “Sintering is the process by which raw materials - either powders or liquids - are converted into a ceramic material,” says Cheryl Xu, co-corresponding author of a paper on this research and a Professor of Mechanical and Aerospace Engineering at North Carolina State University (NCSU). “For this work, we focused on an ultrahigh temperature ceramic called hafnium carbide (HfC). Traditionally, sintering HfC requires placing the raw materials in a furnace that can reach temperatures of at least 2,200
New Spacecraft Power System Passes First TestTBMG-5354408/01/2025
A spacecraft power system that combines the technological know-how of engineers and scientists at the University of Leicester and NASA Glenn has passed its first test with flying colors.
New Laser Technique Revolutionizes Ultra-High Ceramic Manufacturing for SpacecraftTBMG-5358908/01/2025
A new technique that leverages the concept of sintering, can be used to create ceramic coatings, tiles or complex three-dimensional structures, which allows for increased versatility when engineering new devices and technologies.
A 3D Visibility Label for Mobility Coatings: Enhancing Traffic Safety Through Color and Sensor Perception12-09-02-000907/22/2025
The mobility industry is rapidly advancing towards more autonomous modes of transportation with the adoption of sophisticated self-driving technologies. However, a critical challenge, being the lack of standardized norms for defining, measuring, and ensuring vehicle visibility across various dynamic traffic environments, remains. This lack of awareness of visibility is hindering the development of new regulations for vehicle visibility and the controlled transition to a fully-integrated autonomous future. While current efforts focus on improving sensing technologies like computer vision, LiDAR systems, and sensor fusion development, two key issues remain unresolved: 1 The absence of a representative and realistic three-dimensional color visibility model for measuring and comparing the visibility of complex shapes with large but varying color coated three-dimensional surface areas. 2 The need for enhanced visibility solutions that improve visibility and vehicle detectability for all
Mijnen, Paul W., Moerenburg, Joost H.
Brazing, Gold-Nickel Alloy Filler MetalAMS2662A (Current)07/16/2025
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
Nickel Alloy, Corrosion- and Heat-Resistant, Sheet, Strip, and Plate 62Ni - 21.5Cr - 9.0Mo - 3.7Cb (Nb) (Alloy 625) Solution Heat TreatedAMS5869E (Current)07/14/2025
This specification covers a corrosion- and heat-resistant nickel alloy in the form of sheet, strip, and plate up to 1.000 inch (25.40 mm) in nominal thickness.
AMS F Corrosion and Heat Resistant Alloys Committee
Application of AMS3144 Anodic Electrodeposition PrimerAS8491 (Current)07/09/2025
This standard establishes the recommended requirements for application of AMS3144 anodic electrodeposition primer to aerospace components. Adherence to these requirements will help facilitate satisfactory performance of the applied primer.
AMS G8 Aerospace Organic Coatings Committee
Steel, Corrosion-Resistant, Sheet, Strip, and Foil 19Cr - 9.5Ni (304) Cold Rolled, 125 ksi (862 MPa) Tensile StrengthAMS5501G (Current)07/09/2025
This specification covers a corrosion-resistant steel in the form of sheet, strip, and foil.
AMS F Corrosion and Heat Resistant Alloys Committee
Coating, Corrosion-Preventative, for Aircraft Integral Fuel Tanks for Use to 250 °F (121 °C)AMSC27725E (Current)07/01/2025
This specification establishes requirements for three types of corrosion-preventative coatings for protection of aircraft integral fuel tanks.
AMS G8 Aerospace Organic Coatings Committee
Primer, Anodic Electrodeposition for Aircraft ApplicationsAMS3144B (Current)06/30/2025
This specification establishes the requirements for a waterborne, corrosion-inhibiting, chemical- and solvent-resistant, anodic electrodeposition epoxy primer capable of curing at 200 to 210 °F (93 to 99 °C).
AMS G8 Aerospace Organic Coatings Committee
Increasing Wear Strength and Life Cycle of Tamping Machine Tool by Silicon Carbide Coating for Railway Maintenance05-19-02-001106/19/2025
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
CLAMP, LOOP, PLAIN, SUPPORT, AIRCRAFTAS5587C (Current)06/17/2025
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Steel Tubing, Seamless, Round 0.95Cr - 0.20Mo (0.28 - 0.33C) (SAE 4130) 95 ksi (655 MPa) Tensile Strength Aircraft QualityAMS6374F (Current)06/17/2025
This specification covers an aircraft-quality, low-alloy steel in the form of round, non-welded tubing free from OD surface seams.
AMS E Carbon and Low Alloy Steels Committee
Aluminum Alloy, Extrusions 4.5Cu - 0.85Si - 0.80Mn - 0.50Mg (2014-T6) Solution and Precipitation Heat TreatedAMS4153N (Current)06/17/2025
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing up to 32 square inches (206 cm2) in area (see 8.6).
AMS D Nonferrous Alloys Committee
Hard Anodic Coating of Magnesium Alloys Alkaline, Non-Chromate Type, High VoltageAMS2466D (Current)06/17/2025
This specification covers the requirements for a hard anodic coating on magnesium alloys and the properties of the coating.
AMS B Finishes Processes and Fluids Committee
Modern Low Friction Coating Technology for Automotive Tribology2025-01-024706/16/2025
The aim of this work is to present the overviewing results of the low friction coating technology for modern automotive application with the themes, e.g. electric vehicle (EV), R&D trends and bioethanol fuel application. According to Forbes, China, armed with EV, could have several companies among the top 10 global brands by sales in 2030. EV’s friction is more severe than traditional powertrain friction. For the protection of EV’s wear and friction, the coatings, diamond like carbon (DLC) and CrCuN, are compared in the literature. Global coating companies developed with the keywords: hybrid process, low-temperature coating process for polymer material. Last coating conferences showed R&D trends: coating for polymer materials, tetrahedral amorphous carbon (taC) coating, low-temperature coating process and multi-elements containing coatings. In Korea, research institutions, universities and Hyundai Motor Group have a long-term project for the development of ultralow friction coatings of
Cha, Sung Chul, Moon, Kyoung Il, Kim, Jongkuk, Park, Chang Ho, Kim, Dong Sik
Film Cast PTFE Liner and Tubing: An Inside Look at Quality from a Manufacturing PerspectiveTBMG-5328406/01/2025
2025 Ford Expedition: New friendly features and a Tremor for legit off-roading25AUTP06_1506/01/2025
Ford has engineered the 2025 Expedition with an eye to putting it at the top of the large SUV class in which it has usually been a contender. With loads of tech that works well and is controlled easily, friendly features and a highly capable new Tremor off-road edition, it offers plenty of justifications for its pricing. SAE Media was hosted by Ford in Louisville, Kentucky, for a drive of various Expedition trim levels, including a first-hand view of the Tremor's off-road prowess. Among the useful features is the new Split Gate, of which the top 75% lifts like a traditional SUV liftgate. The utility comes in with the lower 25%, which drops like a truck tailgate and can support up to 500 pounds for your football tailgating or other purposes. And avoiding a potential user annoyance is available Open-on-Approach, which opens both gate portions by merely standing near the back of the Expedition. The design of the upper part of the Split Gate, by the way, evokes the apocryphal quote from
Clonts, Chris
Coating System, Advanced Performance, for Exterior Aerospace ApplicationsAMS-STD-32239 (Current)05/05/2025
This specification establishes requirements for coating systems having high durability for use as aircraft exterior surface finishes. These coating systems normally are comprised of a surface treatment, a primer, and a topcoat. Alternatively, a coating system may be comprised of a surface treatment and a unicoat. Testing includes use of a chemical stripper for removal and a cleaning compound for topcoat washing, but these components are not a part of the coating system.
AMS G8 Aerospace Organic Coatings Committee
Powder Coating MaterialAMS3143D (Current)05/03/2025
This specification establishes requirements for thermoset protective coatings in powder form.
AMS G8 Aerospace Organic Coatings Committee
Chemical Film Treatment for Aluminum Alloys General Purpose CoatingAMS2473K (Current)05/03/2025
This specification establishes the requirements for chemical-film (conversion) coatings on aluminum alloys.
AMS B Finishes Processes and Fluids Committee
Steel, Corrosion and Heat-Resistant, Honeycomb Core Resistance Welded, Square CellAMS5850E (Current)04/28/2025
This specification covers a honeycomb core fabricated from a corrosion and heat-resistant steel.
AMS F Corrosion and Heat Resistant Alloys Committee
Study on Flex Fuel Compatible Coatings for Automotive Fuel Tank2024-32-007604/18/2025
Reducing CO2 emissions is now a major focus in India heading towards net zero emissions by 2070. India is the 3rd largest automobile market in the world and the transportation sector is the 3rd largest CO2 emitter. In this direction, it is necessary to reduce the carbon footprint from the automobile sector to combat climate change. The adoption of sustainable biofuels such as ethanol will enable us to reduce emissions, as ethanol is carbon neutral fuel. However, vehicle manufacturers are facing challenges in manufacturing flex fuel compatible parts in the vehicle mainly fuel systems. Ethanol has both nonpolar and polar bonds, making it miscible to both gasoline and water, thereby water contamination is inevitable in ethanol blend fuels. In addition, control of ethanol contamination by sulfates and chlorides during ethanol production is challenging. Thus, ethanol blend fuels are considered more corrosive and tendency towards deposit formation than normal gasoline fuels. Design and
Pandi, Dinesh Babu, Shanmugam, Gomathy Priya, Nagarkatti, Arun, Gopal, Manish, Anbalagan, Prathap
Reducing the Waste of Plating Solution for Magnetostrictive Torque Sensors2024-32-000604/18/2025
The power assist system of an electric bicycle uses a magnetostrictive torque sensor to detect the pedal force based on the magnetic properties of the crankshaft, which change according to stress. Fe–Ni alloy plating is used to coat the surface of the crankshaft with a magnetic film to enhance the magnetostrictive effect. However, the sensor performance decreases as the plating solution degrades, which necessitates replacement of the plating solution. In this study, experiments were performed to investigate how to prevent or mitigate degradation of the plating solution to reduce waste. The amounts of carbon and sulfur in the magnetic film were found to increase with degradation of the plating solution. The carbon derived from organic reducing agents and their decomposition products, and the sulfur derived from stress relievers and their decomposition products. A method was developed for reducing the amounts of carbon and sulfur in the magnetic film, which would help maintain the sensor
Ohnishi, Hiromichi
Mechanical Analysis of a Non-Pneumatic Tire’s Spokes2025-01-832704/01/2025
Mechanical analysis was performed of a non-pneumatic tire, specifically a Michelin Tweel size 18x8.5N10, that can be used up to a speed of 40 km/h. A Parylene-C coating was added to the rubber spoke specimens before performing both microscopic imaging and cyclic tensile testing. Initially, standard ASTM D412 specimens type C and A were cut from the wheel spokes, and then the specimens were subjected to deposition of a nanomaterial. The surfaces of the specimens were prepared in different ways to examine the influence on the material behavior including the stiffness and hysteresis. Microscopic imaging was performed to qualitatively compare the surfaces of the coated and uncoated specimens. Both coated and uncoated spoke specimens of each standard type were then subjected to low-rate cyclic tensile tests up to 500% strain. The results showed that the Parylene-C coating did not affect the maximum stress in the specimens, but did increase the residual strain. Type C specimens also had a
Collings, William, Li, Chengzhi, Schwarz, Jackson, Lakhtakia, Akhlesh, Bakis, Charles, El-Sayegh, Zeinab, El-Gindy, Moustafa
Single-Shot Polarization Imaging System Provides Complete PictureTBMG-5281604/01/2025
Companies have invested heavily to improve color in digital imaging, but wavelength is just one property of light. Polarization — how the electric field oscillates as light propagates — is also rich with information, but polarization imaging remains mostly confined to table-top laboratory settings, relying on traditional optics such as waveplates and polarizers on bulky rotational mounts.
Mitigating Paint Blistering Defects in Aluminum Casted Parts: A QC Story Approach Utilizing Computed Tomography2025-01-822904/01/2025
Blistering in aesthetic parts poses a significant challenge, affecting overall appearance and eroding brand image from the customer's perspective and blister defects disrupt painting line efficiency, resulting in increased rework and rejection rates. This paper investigates the causes and effects of blistering, particularly in the context of internal soundness of Aluminum castings, emphasizing the crucial role of Computed Tomography in defect analysis. Computed Tomography is an advanced Non-Destructive Testing technique used to examine the internal soundness of a material. This study follows a structured 7-step QC story approach, from problem identification to standardization, to accurately identify the root Cause and implement corrective actions to eliminate blister defect. The findings reveal a strong link between internal soundness and surface quality. Based on the root cause, changes in the casting process and die design were made to improve internal soundness, leading to reduced
D, Balachandar, Nataraj, Naveenkumar
Three-Body Abrasive Wear Surface Characterization of Military Diesel Engine Piston Rings and Cylinder Bores2025-01-834604/01/2025
Two 50-hr engine dynamometer tests were conducted on 12-cylinder diesel military engines with differing piston ring sets. Engine A exhibited more than double the oil consumption over engine B. An investigation was conducted to explain why the oil consumption differed by employing several posttest analytical techniques including cylinder bore geometry measurements, surface metrology, wear characterization, and chemical analysis on the piston rings and cylinder wall coatings. The 3D colormaps of cylinder bore deformation showed uneven volumetric deformation through the piston stroke instead of 2D plane deformation. It was found that the primary reason of high oil consumption was direct loss of sealing between the piston, piston ring and cylinder bore due to predominately abrasive wear, three-body abrasive wear and bore polishing. Furthermore, the compromised sealing of the combustion chamber led to blow-by. Carbon deposits, corrosive byproducts, surface abrasives, loss of desired surface
Thrush, Steven, Chen, Aijie, Foley, Michael, Sebeck, Katherine, Boufakhreddine, Ziad
A New Methodology to Characterize the Influence of Paint Baking and Pre-Straining on the Tensile Properties of Third Generation Advanced High Strength Steels2025-01-822304/01/2025
The current ASTM A653 standard for determining the bake hardening index (BHI) of sheet metals can lead to premature fracture at the transition radius of the tensile specimen in high strength steel grades. In this study, a new test procedure to characterize the BHI was developed and applied to 980 and 1180 MPa third generation advanced high strength steels (3G-AHSS). The so-called KS-1B methodology involves pre-straining over-sized tensile specimens followed by the extraction of an ASTM E8 sample, paint baking and re-testing to determine the BHI. Various pre-strain levels in the range of 2 to 10% were considered to evaluate the KS-1B procedure with select comparisons with the ASTM A653 methodology for pre-strain levels of 2 and 8%. Finally, to characterize the influence of paint baking at large strain levels, sheared edge conical hole expansion tests were conducted. The tensile mechanical properties of the 3G steels after paint baking were observed to be sensitive to the pre-strain with
Northcote, Rhys, Berry, Avalon, Narayanan, Advaith, Tolton, Cameron, Lee, Haea, Smith, Jonathan, McCarty, Eric, Butcher, Cliff
In-Situ Nanoindentation and Finite Element Analysis for Evaluating the Young’s Modulus of Anode Current Collectors in Lithium-ion Batteries2025-01-813304/01/2025
As the utilization of lithium-ion batteries in electric vehicles becomes increasingly prevalent, there has been a growing focus on the mechanical properties of lithium-ion battery cores. The current collector significantly impacts the tensile properties of the electrode and the internal fracture of the battery cell. The stripping process tends to cause additional damage to the current collector, so tensile testing is not able to obtain in-situ mechanical properties of the current collector. Therefore, nanoindentation tests are required to acquire the in situ mechanical properties of the current collector. Nanoindentation testing represents the primary methodology for the determination of the mechanical properties of thin films. The Oliver-Pharr method is the standard approach used by commercial indentation instruments for the evaluation of mechanical properties in materials. Nevertheless, this approach is constrained by the limitations imposed by the sample boundary conditions. To
Dai, Rui, Sun, Zhiwei, Park, Jeongjin, Xia, Yong, Zhou, Qing
Establishment of Failure Simulation Models for Bonding of Carbon Fiber Laminated Skins and Cores in Monocoque Structures Based on Formula Student Racing Cars2025-01-800604/01/2025
In Formula SAE , the primary function of the frame is to provide structural support for the different components and withstand the applied load. In recent years, most Formula Student teams worldwide to adopt monocoque made of carbon fiber composites, which are lighter and stronger. Enhancing the mechanical performance of carbon fiber laminates has been a key focus of research for these teams. In three-point bending tests, significant stress at the adhesive layer between the skin and the core material at both ends of the laminate, often lead to potential adhesive failure. Consequently, experimental boards often exhibit delamination between the outer skin and the core material, and premature core crushing, which compromises the mechanical performance of the laminate and fails to pass the Structural Equivalency Spreadsheet. Therefore, it is necessary to consider the influence of the bonding factor of toughened epoxy prepreg film on the mechanical properties of the laminated plate. This
Ning, Zicheng
Advanced Characterization of Mechanical and Cyclic Fatigue Properties of Aluminum Cast Materials for Optimized Industrial Applications2025-01-823704/01/2025
Given the strategic importance of aluminum cast materials in producing lightweight, high-performance products across industries, it is fundamental to assess their mechanical and cyclic fatigue properties thoroughly. This investigation is primarily for optimizing material utilization and enhancing the efficiency and reliability of aluminum cast components, contributing to significant conservation of raw materials and energy throughout both the manufacturing process and the product's lifecycle. In this study, a systematic material investigation was conducted to establish a reliable estimation of the fatigue behavior of different aluminum cast materials under different loading ratios and elevated temperatures. This paper presents an analysis of the statistical and geometrical influences on various aluminum alloys, including AlSi10MnMg, AlSi7Mg0.3, and AlSi8Cu3Fe, produced via pressure die casting and gravity die casting (permanent mold casting), and subjected to different heat treatment
Qaralleh, Ahmad, Niewiadomski, Jan, Bleicher, Christoph
Primer Zinc MolybdateAMS3117B (Current)03/25/2025
This specification covers a zinc molybdate primer in the form of a liquid.
AMS B Finishes Processes and Fluids Committee
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