Browse Topic: Glass

Items (2,121)
The malfunction of the aircraft windshield electric heating system, particularly arc discharge, poses a serious threat to flight safety by causing glass breakage. A systematic study was conducted on the causes and effects of arc faults on windshield structural integrity, employing macroscopic observation, microscopic analysis, and energy dispersive spectroscopy (EDS) following a windshield fracture incident. The results indicate that arc discharge typically occurs at the interface between the heating film busbar and adjacent structures. Localized high temperatures cause the outer glass to fracture, generating radial cracks. The ablation of the busbar silver coating and the carbonization of the PVB interlayer are direct evidence of arc action, whereas the heating wire remains a passive component affected by the high-temperature environment. The fault is primarily attributed to local disbonding at the busbar interface and moisture ingress. Based on the findings, recommendations are proposed for process optimization and inspection method improvement, providing a basis for the safe design and maintenance of windshield structures.
Chen, LiFeng, YanpengDing, Keqin
Electronic substrates and copper-clad laminates are widely used in modern life, particularly in electronic products such as coastal communication base stations and ship communication and navigation system. In these environments, salt particles carried by sea fog can adhere to the surface of the substrates along with moisture, leading to salt-alkali corrosion of the products. As a core material in electronic components, electronic-grade glass fiber urgently requires investigation into its durability under salt-alkali conditions. Therefore, this study focuses on a specific type of electronic-grade glass fiber and explores its corrosion behavior in three different environments: 2 mol/L NaOH, 1 mol/L cement solution, and 3.5 % NaCl. Soaking durations of 6, 12, 24 hours and 3, 7, and 14days were selected as key parameters. The mechanical properties and surface morphology of the fibers before and after corrosion were observed and analyzed. Experimental results indicate that the glass fiber exhibits higher durability in saline solutions than in alkaline environments. This study provides theoretical support for evaluating the long-term performance of Electronic grade glass fibers in practical applications. It also contributes to the optimization of raw materials and manufacturing processes, enhancing the performance of such fibers in salt-alkali conditions, and offers valuable reference for future research on glass fiber-reinforced composites.
Pu, QixinSun, SiqiFang, QiangDong, ShuoLi, PengWang, YuZhang, MengxuanZhang, YuboYang, WenfengGuo, Peng
The intent of this specification is for the procurement of carbon fiber and fiberglass epoxy prepreg products with 350 °F (177 °C) cure for aerospace applications; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the production quality assurance section (see 4.3) of this base specification, AMS6891.
AMS P17 Polymer Matrix Composites Committee
This Purchase Specification (PS), AMS3970/5, specifies the batch release and delivery requirements for the companion non-structural glass fiber fabric prepreg. This specification also defines the procedure and requirements for storage life extension of materials purchased against this specification. It is only applicable for materials which are qualified and shall be carried out within the responsibility of the purchaser and under control of its Quality organization.
AMS CACRC Commercial Aircraft Composite Repair Committee
The study proposes the use of Carbon Fiber Reinforced Plastic (CFRP) sandwich composites configurations for structures interfacing cryogenic tankages. To address the design challenge posed by high thermal contractions in metallic tanks after cryogenic propellant filling, the study incorporates slits near the tank interfaces. Additionally, to minimize the transfer of cryogenic temperatures into these interfacing parts, the sandwich structure features interface end attachment made of thermally insulating Glass Fiber Reinforced Plastic (GFRP) material. Analytical and Finite Element (FE) studies were conducted on a typical cylindrical cryogenic intertank structure to demonstrate the proof of concept. These studies included analytical design using MATLAB based codes, parametric analyses with simplified shell element models and detailed 3D sector models using solid elements. The parametric studies assessed the effects of the number and dimensions of slits to achieve an optimal design, while the detailed 3D sector model provided refined results, validating the adequacy of the proposed concept. Proof-of-concept investigations on the case study sandwich intertank structure demonstrate a notable 30% improvement in mass efficiency compared to the truss configuration and 45% improvement relative to the closed shell metallic configuration, thereby validating the mass efficiency of the proposed design configuration.
Bhalerao, Sandesh PopatGupta, Yogesh KumarMadhukumar, P.
Unmanned Aerial Vehicles (UAVs) demand structural materials that are lightweight, strong, impact-resistant, and durable in diverse environments. The synthetic fiber reinforced polymer composites have varying mechanical performance depending on the fiber matrix interfacial properties. This research analyzes the influence of Graphene Oxide (GO) nano fillers on mechanical properties of composites. Firstly, the epoxy resin was modified by incorporating different weight percentage of Graphene Oxide. This resin was used to make an composite laminate using different materials (Carbon, Glass and combination of these fibers). Then the composites were put through the tensile, compression, flexural tests. The synthetic fiber reinforced polymer composites have a significant improvement in mechanical properties due to the addition of Graphene Oxide.
Manoharan, DineshLangford, PeterM.K., PadmanabhanR, PrithvirajRajkumar, SubbiahKarthikeyan, RavikumarVeeramuthu, BalasubramaniyanGunaseelan, JohnT, Thangaraj
This study systematically evaluated the wear resilient performance of AZ61 magnesium alloy reinforced with 15 wt.% SiC and diverse amounts of multi-walled carbon nanotubes (MWCNTs) under dry sliding circumstances adopting pin-on-disc apparatus (ASTM G99). To identify the influence of factors like sliding speed (SS) (1-3 m/s), axial load (AL) (10-30 N), and MWCNT concentration (0-3 wt.%) that affect tribological performance, experiments were developed using a Central Composite Design (CCD) under Response Surface Methodology (RSM). SEM micrographs revealed a dispersion optimum near 2 wt.% MWCNT, where CNTs anchor to SiC and bridge the α-Mg matrix, while 3 wt.% shows agglomerates and micro-voids. Findings showed that wear loss (WL) and friction coefficient (CoF) was greatly amplified by increasing AL owing to localized heating and contact stresses. A compacted tribolayer was formed by increasing SS, which decreased WL but marginally raised the CoF. At low AL (10 N), SS (2.09 m/s), and 2.12 wt.% MWCNT, the wear resistance was significantly improved by improving load transfer and creating a lubricating carbon-rich coating, resulting in a decreased WL of 0.006 g. The CoF persisted within the range of 0.19 to 0.28. Agglomeration of MWCNTs caused increased WL and CoF when the MWCNT content is increased above 2 wt.%. Worn-surface microscopy at the optimum showed fine wear tracks and a continuous carbon/oxide glaze, evidencing a lubricious CNT-rich third-body film, whereas high AL/low MWCNT produced deep grooves and delamination.
Senthilkumar, N.
This research investigates the fabrication and evaluation of Delrin (polyoxymethylene, POM) composites reinforcing 5-20 wt.% chopped ramie fiber (RF). The polymer composites were fabricated via the injection moulding technique. Glass transition temperature (Tg), thermal conductivity, Vicat softening temperature (VST), heat deflection temperature (HDT), melt flow index (MFI), and coefficient of linear thermal expansion (CLTE) were the various thermal characteristics of the sustainable composites that were systematically evaluated as per the ASTM standards. The addition of RF drastically altered the Delrin matrix's performance. Among the formulations, the composite with 15 wt.% RF had the best combination of properties: higher VST and HDT values, which provide greater dimensional stability at high temperatures; lower CLTE, resulting in less thermal expansion; comparatively better thermal conductivity; and improved heat dissipation. Eventually, there was a moderate drop in the MFI, indicating more rigid polymer chains that restrict the flowability of the composite, thereby increasing its heat-withstanding capabilities. DSC analysis revealed a slight upward shift in Tg and increased crystallinity, suggesting restricted polymer chain mobility and enhanced load transfer at 20 wt.% RF loadings, agglomeration effects, and weaker interfacial bonding with the matrix led to deterioration in properties. Aircraft cabin components like interior panels, ducting supports, and lightweight non-structural fittings requires dimensional stability, thermal resistance, and mechanical reliability under fluctuating flight conditions.
S, ThirumalvalavanSenthilkumar, N.Selvarasu, S
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 optics prior to assembly to relieve internal stress, and (ii) using step-torquing method to fasten the screws, to gradually distribute applied loads and reduce localized stress peaks. Post-assembly observation over three days confirmed a significant reduction in crack initiation. The combined annealing and step-torquing approach demonstrated a substantial reduction in crack generation probability, providing a practical and repeatable process for enhancing the robustness of polymeric optic assemblies. This work contributes a generalizable methodology for mitigating assembly-induced failures in advanced polymer materials and supports broader adoption of lightweight, high-performance optics in aerospace applications.
S, NikhilSingh, Abhimanyu KumarKatageri, PraveenSP, PradeepChandra, Praveen
AMS6885/5 is the Material Specification (MS) which defines the requirements of a unidirectional carbon fiber tape epoxy repair prepreg capable of curing under vacuum for repair of carbon fiber reinforced epoxy structures. It also defines the requirements of an epoxy film adhesive to be applied in a co-bonding process with the prepreg for solid laminate and sandwich bonding.
AMS CACRC Commercial Aircraft Composite Repair Committee
Specifications, test methods, and usage provisions for safety glazing materials used for glazing of motor vehicles and motor vehicle equipment operating on land highways.
Glazing Materials Standards Committee
Materials can exhibit significantly different mechanical behaviors compared to quasi-static conditions at high strain rates (> 100 s-1). High strain rate tests using setups such as SHPB (Split-Hopkinson Pressure Bar) can provide, in a practicable manner, the stress-strain relations for a material at high strain rates. Such properties are vitally needed for activities such as simulation-driven impact safety design of composite structures deployed in the form of automotive body parts and assembly, and other sub-systems. Although the behaviors of isotropic and ductile materials such as various metallic alloys appear to have been extensively studied and reported in literature, dependence of mechanical properties of fiber-reinforced composites especially in different off-axis directions are extremely difficult to come across. To fill up this void, a detailed experimental study has been carried out on high strain rate mechanical characterization of a laminated orthotropic glass/epoxy composite using an in-house SHPB powered by a compressed gas gun and equipped with a high speed DAQ (data acquisition) system. A unique feature of the current study is the reporting of stress-strain curves at high strain rates when specimens are loaded in off-axis directions i.e. at angles to the principal direction (viz. 0°, 15°, 30°, etc.). The results highlight the substantive effect of strain rate on properties such as failure strength of the considered composite, and its visibly distinct behaviors in various off-axis loading directions.
Bawa, PrashantDeb, AnindyaBarui, AnanyaZhu, Feng
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 based Chaboche NLK model is implemented as a macro-mechanical phenomenological model based on test data with random fiber orientation. After material modelling as described above the thermo-mechanical finite element (FE) simulation has been conducted on Connector panel assembly with temperature cycling from -40°C to 80°C. The assembly under consideration is composed of busbars, insert mold and outer connector body of plastic PA66GF. It is observed from the simulation result that though the equivalent plastic strain is much higher at 80°C in comparison to the same at -40°C, the equivalent von Mises stress is comparatively lower at 80°C than at -40°C because of Bauschinger effect while reversing load, which in turn validates the implementation of proper kinematic hardening material model to address the physical phenomenon. Finally, the FE model is validated through characterized crack initiation site in the plastic component comparing with equivalent plastic strain, von Mises stress and stress triaxiality evaluated from simulated result.
Basu, ParichaySrinivasappa, Naveen
This study focuses on the vibration analysis of hybrid composite laminated plates fabricated from E-glass Fiber and areca Fiber reinforced with epoxy resin. The hybrid laminates were prepared using the Vacuum Assisted Resin Transfer Moulding (VARTM) process with different stacking sequences and Fiber ratios, where brake lining powder was also incorporated as a filler in selected configurations to enhance mechanical and damping properties. The fabricated plates (280 × 280 mm) were subjected to experimental modal analysis using an impact hammer and accelerometer setup, with data acquisition carried out through DEWESoft software. Natural frequencies and damping ratios were determined under three boundary conditions (C- C-C-C, C-F-C-F, and C-F-F-F). The results revealed that Plate 1, with E-glass outer layers, areca reinforcement, and filler addition, exhibited the best vibration performance, achieving a maximum natural frequency of 332.8 Hz under C-C-C-C condition, while Plate 2 showed a balanced response and Plate 3 demonstrated higher stiffness but lower damping capability. These findings suggest that incorporating areca Fiber in combination with E-glass not only reduces weight but also improves damping without significantly compromising structural integrity. The developed hybrid composites hold strong potential for lightweight, vibration-sensitive applications such as automotive interiors, marine structures, construction panels, and sports equipment, where both sustainability and performance are critical.
D R, RajkumarO, Vivin LeninR, SaktheevelR G, Ajay KrishnaNg, Bhavan
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 behavior in injection-molded thermoplastic components, incorporating material anisotropy. The simulation results demonstrate that anisotropic modeling effectively captures the influence of short fiber orientations, revealing localized stress distributions and macroscopic failure indicator results. Outcomes of the current approach are compared with isotropic simulations that exclude injection molding data, highlighting the advantages of incorporating process-induced anisotropy. These findings enhance understanding of the mechanical performance of short fiber-reinforced thermoplastics and provide a foundation for future integration of multi-scale finite element tools. The application of this methodology supports the development of cost-effective and efficient virtual product designs by accurately predicting deformation and failure under various loading conditions.
T, KalingaYanamadala, Dharma TejaMattupalli, VenkataChirravuri, BhaskaraMiller, Ronald
In recent decades, Computer-Aided Engineering (CAE) has become increasingly critical in the early stages of vehicle development, particularly for performance improvement and weight optimization. At the core of this advancement lies the accuracy of CAE models, which directly impacts design insights and reliable TEST-CAE correlation. Yet, accurately replicating real-world physical systems in virtual environments remains a significant challenge. This research introduces a structured methodology for improving correlation in door system models. It focuses specifically on reducing glass regulator operating noise, a common design issue that can lead to unwanted sounds and passenger discomfort. Traditional CAE models often fail to predict this problem, exposing the limitations of virtual-only validation. To address this gap, the study proposes a modal correlation-based approach aligned with actual assembly stage conditions. This strategy enables more precise assessment of the glass regulator’s operating behavior, substantially improving the correlation accuracy when compared to the initial model. The results affirm that this enhanced approach offers a reliable means of detecting noise issues early in the product development cycle. The refined model increases predictive accuracy and lays the foundation for improved cost efficiency, weight reduction, and passenger satisfaction. This methodology holds promise for advancing virtual validation practices in the automotive industry, providing engineers with powerful tools to optimize design and ensure higher-quality outcomes from the earliest development phases.
Panuganti, Naresh KumarChoi, Seungchan
The use of polymeric materials and polymer -based composites as alternatives to metals in conventional applications is a widely adopted strategy. These materials provide advantages in terms of processability, cost-effectiveness, and, most notably, weight reduction. This study aimed to develop and optimize the injection molding process for producing PA9T (Polyphthalamide 9T) components reinforced with varying amounts of glass fiber to achieve optimal mechanical and physical properties. To enhance mechanical performance, different glass fiber loadings were investigated. The study employed the Taguchi method with an L9 orthogonal array design. The selected variable parameters were material composition (PA9T reinforced with 30, 35, and 50 wt% glass fiber), injection pressure (1000, 1500, and 2000 bar), injection temperature (320, 330, and 340 °C), and injection speed (100, 125, and 150 mm/s). The Taguchi method was chosen because it allows for the identification of optimal process parameters and the evaluation of their influence on material properties while requiring significantly fewer experimental runs compared to a full-factorial 34 design. The materials were evaluated based on mechanical properties through tensile and flexural tests using a Universal Testing Machine. The density of the injected specimens was measured using the Archimedes principle, while fiber-matrix adhesion, porosity morphology, and fracture behavior were analyzed via scanning electron microscopy (SEM). Results indicated that the glass fiber content had the most significant influence on material strength, followed by injection pressure, temperature, and speed, in that order. The study identified 1000 bar, 320 °C, and 100 mm/s and 50 wt% glass fiber as the optimal processing parameters, ensuring that specimens produced under these conditions achieved mechanical properties such as 230 MPa stress at break and elastic modulus of 19,3 GPa.
Mendonça, Arthur S.Michelotti, Alvaro CantoBerto, Lucas F.Salvaro, Diego B.Binder, Cristiano
Materials science and engineering are essential for advancing energy-efficient mechanical systems through lightweight structures and friction reduction. Among engineering polymers, polyphthalamides (PPA) are widely used for their superior thermochemical and mechanical properties. This study investigates the influence of polytetrafluoroethylene (PTFE) on the mechanical and tribological performance of a commercial polymer matrix composite (PMC) reinforced with 30wt% glass fiber. Self-lubricating composites were manufactured by injection molding with PTFE contents ranging from 0-15 wt%. Density was measured using Archimedes’ method. Mechanical properties were measured through ISO 527 tensile testing, while tribological behavior was evaluated using ball-on-flat reciprocating tests under 189N (630 MPa), 2 H frequency, and 10 mm strokes for 60 minutes, employing a 10 mm diameter AISI 52100 steel sphere as counter-body. Friction coefficient (COF) was monitored throughout testing, and wear mechanisms were investigated using white-light interferometry (WLI), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS). Wear volumes were obtained from contact profilometry. Results show that PTFE addition reduced mechanical strength decreasing by 7.9%, 8.5% and 14.8% for 2%, 5% and 15% PTFE, respectively. In contrast, tribological performance improved, with COF stabilizing between 0.03-0.08 and wear rate decreasing from 5.6 × 10-4 mm3/N.m (no lubricant) to 1.0 × 10-4 mm3/N.m for 2 and 5% PTFE. At 15% PTFE, wear rate and COP increased to 2.3 × 10-4 mm3/N.m and 0.08, respectively. EDS analysis detected fluorine on the wear surfaces, confirming the formation of PTFE-rich tribolayers. However, excessive PTFE compromises mechanical integrity due to the formation of large reservoirs, leading to increased deformation and wear under high pressure. Thus, optimal performance results from balancing PTFE content and mechanical in robustness.
Hromatka, MatheusSalvaro, Diego B.Binder, CristianoMichelotti, Alvaro C.Berto, Lucas F.
There is a growing demand for new materials that meet mechanical and structural performance requirements, with specific properties, especially in the automotive industry. From a context of innovation and global needs to be met, there is the appreciation of composite materials, specifically applied in the automotive sector, since these can be obtained from the combination of two or more different materials, obtaining certain properties from the individual characteristics of its phases, expanding the availability of materials to be used in this sector. In recent years the use of natural fibers in composite materials for automotive applications has gained relevance due to factors such as sustainability, low weight and good mechanical properties. The attempt to combine innovation and environmental preservation make such applications promising, aiming to obtain ecological solutions, considering that natural fibers of vegetable origin such as sisal, jute and flax are biodegradable and renewable, being an environmentally friendly alternative compared to synthetic fibers such as glass and carbon. Sisal fiber, for example, is already used in coatings, interior panels and car sound insulation. Therefore, the present work aims to present a review about the general panorama of the use of natural fibers and composites reinforced by such fibers at national level in the automotive sector. For this, will be cataloged articles, dissertations, course completion work etc. for the interval of 2014 to 2025, which are related to this theme, from university libraries, academic platforms or directly in journals dedicated to engineering among other sources of information, being presented the main thermoplastic and thermofix matrices used, such as polypropylene, polyester and epoxy, in addition, the presentation of natural fibers found in Brazil, such as jute, sisal, coconut and curaua. In addition, attending conferences and symposia in the area can provide updated and relevant information to present the main applications, research and trends on the subject. Thus, research on the use of natural fibers in the automotive industry is growing, reflecting the increased demand for more sustainable solutions.
Dias, Roberto Yuri CostaSantos Borges, Larissa dosBrandao, Leonardo William MacedoMendonca Maia, Pedro Victor deSilva de Mendonça, Alian Gomes daFujiyama, Roberto Tetsuo
Studies correlate air pollution with an increase in the incidence of respiratory diseases, affecting lung function and raising hospitalization rates. Among the pollutants associated with these diseases, inhalable coarse particulate matter (PM10) and fine particulate matter (PM2.5) stand out. The emission of particulate matter resulting from the wear of brake pads in light vehicles is the second largest source, accounting for approximately 33% of a vehicle’s total emissions. The particulate matter generated during the braking process can be analyzed through its collection in tests conducted on dynamometers, using enclosure and sampling systems. The development of the dynamometer used was based on the braking cycles described in the SAE J2522:2003 standard, whose main objective is to provide comparative data on different friction materials. Given the variations in particulate matter emissions depending on the composition of the brake pads, as reported in the literature, this study presents an analysis of the emissions from two distinct formulations, as well as a comparison of wear parameters and the surface roughness of the pads. The characterization of the particulate matter was carried out using a sampling system in accordance with ISO 9096:2017, with a sampling duct aligned with the flow duct downstream of the enclosure chamber, and particle retention achieved through fiberglass filters. The airflow velocity was controlled to ensure isokinetic transport conditions in the sampling system, adjusting the connected pump to match the probe velocity. The results show that wear was not uniform between the pairs of brake pads, also revealing differences in the chemical composition of the particulate matter according to the different formulations, consistent with what is reported in the literature, but with similar particle concentrations by size.
Catão, Vítor Gustavo GomesMachado, Amanda RibeiroFiorentin, Felipe KleinSilva, João Pedro AnutoBernardino, Lucas GabrielFiorentin, Thiago AntonioCarboni, Andrea Piga
In this article, a three-dimensional transient CFD simulation method is used to simulate the wind noise of a vehicle model’s external flow field. The transient noise excitation of external noise sources outside each window glass are analyzed, and the statistical energy analysis method is used to calculate the articulation index of the front and rear passenger inside the vehicle. Then, the variation range of the thickness of each window glass is set, and the side window glass is also divided into two types: single-layer glass and laminated glass. After the design parameters are defined, the design space is established. The articulation index of the front and rear passengers and the total weight of the glass are the three design objectives for multi-objective optimization simulation, based on the results of optimization simulation, the change trend of each design parameter and design objective is analyzed; the sensitivity of the design objective to each design parameter is studied; the limit value of the design objective is calculated; the relationship between each design objective is analyzed; and the optimal design proposal that can achieve multiple design objectives at the same time is obtained.
Xiong, ZhenfengZhang, XiaoLiu, PingLi, BoYuan, QingpengChen, ShiwenTo, Chi Hin
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 traffic participants while maintaining color styling freedom. This article presents a new visibility assessment model that measures the three-dimensional Point-of-View (PoV) Visibility of mobility coatings using a 5-parameter Visibility Label. It evaluates how visible a mobility coating color is on a complex three-dimensional vehicle shape from a separate observer’s perspective or an observing device. Key components of this three-dimensional Point-of-View Color Visibility Model include: Moving beyond flat panel color design and measurements to a comprehensive 3D Visibility Model Considering visibility for human vision, computer vision and LiDAR visibility modalities Establishing automotive glossy solid white as reference color The Visibility Label helps users understand how visible complex shapes with different colored coatings are. It quantifies visibility in real-world scenarios, enabling easy comparison between designs and finishes. This simplifies decisions on which coatings enhance visibility most. The article shows that similar colors can have a significant different 3D PoV Color Visibility. It explores ways to enhance this visibility with new color coating technologies, particularly through Crystal Glass Pigment (CGP) formulations that significantly improve 3D color visibility. The example in Appendix B demonstrates an increase in 3D Color Visibility of 200% for Human Visibility and 600% for Full Object Visibility for the addition of 5 weight-percent CGP, and 183% increase for LiDAR Visibility for the addition of 17 weight-percent CGP to an existing silvery metallic automotive refinish color. By emphasizing the importance of 3D PoV Color Visibility in traffic environments where human-controlled, semi- and fully autonomous vehicles coexist, and highlighting the influence of color and shape on vehicle visibility, this comprehensive approach aims to significantly impact road safety today while facilitating a controlled transition to an autonomous future.
Mijnen, Paul W.Moerenburg, Joost H.
Researchers have developed a new type of sensor platform using a gold nanoparticle array. The sensor is made up of a series of gold disk-shaped nanoparticles on a glass slide. When an infrared laser is pointed at a precise arrangement of the particles, they start to emit unusual amounts of ultraviolet (UV) light.
A proprietary metamaterial has been shown to reduce panel vibration. In this particular case, the metamaterial is designed to be attached to the edge of a glass panel and can reduce panel vibration and noise transmission due to wind or other sources into the vehicle interior. Acoustic transmission loss and panel vibration assessments show the benefit of this approach.
Sorenson, SteveLi, XiaopengMoore, JaimeRobison, Scott
Machining metal has its challenges as many shops will attest, but machining glass is another matter – one that Dan Bukaty Jr., President of Precision Glass & Optics (PG&O) is well schooled in. Mr. Bukaty and his 35-person shop manufacture high-end precision glass optics for customers such as IMAX, Intuitive Surgical, Boeing and NASA, to name a few. The products PG&O make can range from the ordinary to the extraterrestrial, such as mirrors that it fabricated for the Hobby–Eberly Telescope to measure dark energy in outer space.
Polymer composites, such as fiber-reinforced plastics (FRPs), are widely used in shipbuilding, aerospace, and automobile industries due to their lightweight and high strengths. In real-world conditions, ship hulls are exposed to harsh environmental factors, including variations in moisture and salinity. FRPs tend to absorb water and moisture, leading to an increase in weight and a reduction in strengths over time, which is undesirable for ship and aircraft structures. This study investigates the reduction in energy absorption and specific energy absorption of glass FRPs (GFRP) and aluminum honeycomb sandwich composites (AHSC) due to exposure to moisture and salinity. Experimental analysis was conducted by immersing the materials in saline and non-saline water. A comparative assessment of the percentage reduction in specific energy absorption (SEA) of GFRP and AHSC is presented. Additionally, the influence of honeycomb parameters such as cell size (CS), foil thickness (FT), and core height (CH) on SEA has been analyzed. Results indicate a 27% reduction in SEA for GFRP and a 7% reduction for AHSC due to water absorption. Furthermore, SEA in AHSC can be improved by changing honeycomb parameters, with foil thickness having the most significant impact on SEA enhancement.
Rajput, ArunKumar, AshwinSunny, Mohhamed RabiusChavhan, Harikrishna
This paper presents a new regression model-based method for accurate predictions of stiffness of different glass laminate constructions with a point-load bending test setup. Numerical FEA models have been developed and validated with experimental data, then used to provide training data required for the statistical model. The multi-variable regression method considered six input variables of total glass thickness, thickness ratio of glass plies as well as high-order terms. Highly asymmetrical, hybrid laminates combining a relatively thick soda-lime glass (SLG) ply joined with a relatively thin Corning® Gorilla® Glass (GG) ply were analyzed and compared to standard symmetrical SLG-SLG constructions or a monolithic SLG with the same total glass thickness. Both stiffness of the asymmetrical laminates and the improvement percentage over the standard symmetrical design can be predicted through the model with high precision.
Yu, ChaoCleary, ThomasJoubaud, Laurentkister, EvanFisher, W Keith
Camera-based mirror systems (CBMS) are being adopted by commercial fleets based on the potential improvements to operational efficiency through improved aerodynamics, resulting in better fuel economy, improved maneuverability, and the potential improvement for overall safety. Until CBMS are widely adopted it will be expected that drivers will be required to adapt to both conventional glass mirrors and CBMS which could have potential impact on the safety and performance of the driver when moving between vehicles with and without CBMS. To understand the potential impact to driver perception and safety, along with other human factors related to CBMS, laboratory testing was performed to understand the impact of CBMS and conventional glass mirrors. Drivers were subjected to various, nominal driving scenarios using a truck equipped with conventional glass mirrors, CBMS, and both glass mirrors and CBMS, to observe the differences in metrics such as head and eye movement, reaction time, and perception of distance. The finds from this study will serve as the baseline measurements for future research regarding off-nominal driving scenarios and hardware failures of CBMS, as well as inform potential future policy regarding CBMS for the use in commercial vehicles in lieu of conventional glass mirrors.
Siekmann, AdamPrikhodko, VitalySujan, Vivek
The incorporation of natural available material into synthetic materials to form a fiber within a single polymer matrix has been ignited since environment concerns become crucial nowadays. Composite materials embedded with two or more types of fibers makes a composite as hybrid. The study of hybridization of natural and synthetic fibers brings out superior mechanical and tribological properties. In our present studies, fabrication of jute & glass fiber reinforced epoxy-based polymer hybrid composites were carried out using resin infusion technique. For comparing the various properties, the composite made of pure jute fiber i.e 100% jute, pure glass fiber i.e 100% glass, the hybrid composite containing 75% jute and 25% glass fiber, 50% jute and 50% glass fiber, and 25% jute and 75% glass fiber were made and its functional behaviors were studied. The results revealed the hybrid composite containing 25% jute and 75% glass fiber possessed maximum tensile strength of 292±5.8 MPa, flexural strength of 188.3±3.7 MPa, impact strength of 130±2.6 kJ/m2, storage modulus of 17050MPa, loss modulus of 2883MPa, and minimum moisture absorption and wear loss. As compared with the obtained values of composite containing pure jute fiber, tensile strength was increased by 346%, flexural strength increased by 278%, impact strength increased by 227%, hardness increased by 184%, storage modulus increased by 431%, loss modulus increased by 454%, moisture absorption decreased by 88% and wear loss decreased by 100% . Thus prepared hybrid composites, could be employed in different automobile components such as panels, fenders, engine components, brake pad materials, bonnets and heat shields.
J, ChandradassT, ThirugnanasambandhamM, Amutha SurabiP, Baskara SethupathiRajendran, RMurugadoss, Palanivendhan
This study focuses on developing and deploying an Unmanned Aquatic Vehicle (UAV) capable of underwater travel. The primary objectives of this project are to detect the presence of dimethyl sulfide and toluene, as well as to identify any potential oil leakage in underwater pipelines. The UAV has a maximum operating depth of 300 m below the water surface. The design of this UAV is derived from the natural design of Rhinaancylostoma, an underwater kind of fish. The maximum operational setting for this mission is fixed at a depth of approximately 300 m beneath the surface of the sea, and the choice of this species is suitable for fulfilling the objectives of this undertaking. This technology will mitigate the risk associated with human interaction in inspection processes and has the potential to encompass various other resources in the future. The initial design data of the UAV is determined using analytical processes and verified formulas. The selection of the airfoil is done by comparing numerous options, such as NACA 0006, NACA 0020, and NACA 0024. The comparison investigation shows that the NACA 0008 has a lower coefficient of drag. ANSYS Workbench tool is utilized for executing computational analysis, encompassing hydrodynamic and hydro-structural simulations. An innovative computational molding technique is utilized as a preprocessing step. Structural examination is conducted in a two-step procedure, utilizing eight different materials. The selected materials for analysis are Boron fiber reinforced polymer (BFRP), AS-Carbon fiber reinforced polymer (CFRP), T-300-CFRP, HMS-CFRP, GY-70-CFRP, Kevlar fiber reinforced polymer, E-Glass fiber reinforced polymer (GFRP), and S-GFRP. The solid model of the UAV is subjected to computational analysis under two distinct loading circumstances. This analysis helps in identifying the most effective materials for future examination of the structure utilizing layer model molding in ANSYS ACP software. Afterwards, hybrid composites are prepared with the imposition of advanced fibers, and so the hydro-structural analyses are computed. The hydrodynamic parameters are calculated, and as a result, the structural performance of UAV is monitored. In the end, the most optimal material is chosen for the developed hydrodynamically efficient UAV's construction, to carry out the application efficiently and reliably.
Veeraperumal Senthil Nathan, Janani PriyadharshiniRajendran, MahendranArumugam, ManikandanRaji, Arul PrakashSakthivel, PradeshMadasamy, Senthil KumarStanislaus Arputharaj, BeenaL, NatrayanRaja, Vijayanandh
The integration of carbon nanotubes (CNT) into composite materials has revolutionized various high-performance industries, including aerospace, marine, and defense, for their exceptional thermal, mechanical, and electrical properties. The critical nature of these applications demands precise control over the manufacturing process to ensure the optimal performance of the CNT-reinforced composites. This study employs the Taguchi approach to systematically investigate and determine the optimal proportion of CNT volume fraction, fiber volume fraction, and stacking sequence in composite materials to achieve the optimal fundamental frequency. The Taguchi method, known for its efficiency in optimizing design parameters with a minimal number of experiments, enables the identification of the most influential factors and their optimal levels for enhancing material properties. Our findings demonstrate that the proper arrangement and proportioning of these components significantly improve the composite's strength, durability, and overall performance. The optimized parameters derived from this study provide a robust framework for manufacturing superior CNT-reinforced composites, advancing their application in critical sectors where performance and reliability are paramount. To ascertain the material properties of the required combination of glass fiber and CNT, Ansys Material Designer was used. A unidirectional fiber in a hexagonal lattice was considered for the material, where the matrix consisted of CNT reinforcement and epoxy resin. To conduct the vibrational analysis of the study, Ansys software was used to model the rectangular composite plate and find the frequencies of the first 6 modes of each variation of factors. The rectangular plate was modeled in Ansys ACP and the frequency analysis was conducted on Ansys Modal. The plate was subjected to clamped boundary conditions and different volume fractions of glass fiber, CNT reinforcement and stacking sequence for the analysis. The results of this study show that out of the three factors considered, the fiber volume fraction is the most influential and the stacking sequence is the next most influential. This gives us an idea on the considerations needed while manufacturing composite plates and most importantly, the applications which they can and cannot be used for due to their fundamental frequency.
B, SrivatsanBalakrishna Sriganth, PranavBhaskara Rao, LokavarapuBiswas, Sayan
This study investigates the frequency response characteristics of laminated composite rectangular plates, focusing on the influence of fiber orientation. The composite plates, composed of 12 layers of glass fiber reinforced polymer composites (GFRP), were chosen for their superior mechanical properties and broad applicability in engineering fields, including the automotive sector. In automotive engineering, these composites are valued for their lightweight properties and high strength, contributing to enhanced performance and fuel efficiency. The analysis employed a combination of finite element methods and Taguchi experimental design techniques to understand how fiber orientation affects the dynamic behavior of these plates. To systematically explore the impact of fiber orientation on the frequency response, the study utilized Taguchi's orthogonal array design. Specifically, the L9 (3^3) and L16 (4^4) orthogonal arrays were employed to structure the experimental runs effectively. These arrays minimize the number of experimental trials while ensuring a comprehensive exploration of the parameter space. Each group of three or four plies was treated as a control factor, with fiber orientation angles varied from 7.5 to 90 degrees. This range was chosen to encompass a wide spectrum of possible orientations, providing a thorough investigation. To identify the optimal fiber orientations for maximizing the frequency response, the study employed signal-to-noise (S/N) ratio analysis. This technique is integral to Taguchi methods, quantifying the robustness of the design by measuring the deviation of the response from the desired target. Higher S/N ratios correspond to better performance and stability, guiding the selection of optimal fiber orientations. Additionally, an analysis of variance (ANOVA) was performed to discern the statistical significance and contribution percentages of the control factors influencing the frequency response. This statistical tool was crucial in identifying the most influential parameters and their respective contributions. The combined use of finite element modeling, Taguchi design techniques, S/N ratio analysis, and ANOVA culminated in a comprehensive understanding of the frequency response characteristics of laminated composite plates. The findings highlight the critical role of fiber orientation in enhancing the frequency response of GFRP composite plates. Optimizing fiber orientation in composite materials can significantly improve vehicle performance by reducing vibrations and enhancing structural integrity.
N, SuhasC V, PrasshanthU, Anish KumarBhaskara Rao, Lokavarapu
Worldwide, glass manufacturing produces at least 86 million tons of carbon dioxide (CO 2) every year. A new type of glass aims to cut this carbon footprint in half. The invention — LionGlass, engineered at Penn State — requires significantly less energy to produce and is much more damage resistant than standard soda lime silicate glass.
The industrial world focuses on developing eco-friendly, natural fibres such as reinforcing lightweight, inexpensive compounds in modern days. Basalt, a rare phenomenon, derives its origins from molten volcanic rocks, which is essential for their cost-effectiveness and offers different glass fibre properties. High mechanical strength, outstanding wear resistance, and exceptional durability in a variety of environmental conditions are all displayed by basalt fibres. These fibres are ideal for reinforcing polymer composites because of their mechanical properties at high temperatures. Furthermore, basalt fibres are appropriate for long-term applications because they resist corrosion and degradation while maintaining structural integrity over time. This article provides a brief overview of basalt fibres as a substitute for glass fibres and as composite materials. Additionally, attempts are being made to draw attention to the expanding field of basalt fibre research. In the review, studies conclude by discussing the evolution of mechanical properties derived from the industrial use of reinforced basalt fibre compounds.
Chidambaranathan, BibinRaghavan, SheejaSoundararajan, GopinathArunkumar, S.Ashok Kumar, R.Rajesh, K.
Car bumpers are protective structures for the occupants of a vehicle during a collision, absorbing impact energy, such a structure is located at the front and rear of the vehicle. Metals were used to manufacture the first bumpers, and it was subsequently assessed that using a different material would reduce their weight, for example plastic, resulting in increased fuel economy and impact absorption. Also, the use of polymers reinforced by glass fibers offer good mechanical strength. This work evaluates the replacement of conventional materials by an ecologically more viable alternative, natural fibers as plastic reinforcement, reducing costs, without considerable loss in the material mechanical properties. Specimens of reinforced composite material were produced with jute fiber. The fibers, obtained through fabrics, were standardized in length of 5.0 mm and 15.0 mm. The matrix phase applied was the unsaturated and pre-accelerated terephthalic polyester resin manufactured by Royal Polymers, and the catalyst MEK V388 was applied to accelerate the material curing process. The production technique was manual lamination from silicone molds with dimensions specified by ASTM D638. The specimens were subjected to tensile strength tests to determine their mechanical properties. The tensile strength of composites with fibers of 5.0 mm and 15.0 mm were: 17.59 (± 4.69) MPa and 21.17 (± 6.42) MPa, respectively. In addition, the appearance and profile of the fracture surface after the tensile test are presented in this work.
Soares, Rafael VilhenaDias, Roberto Yuri Costade Mendonca Maia, Pedro VictorJunior, Waldomiro Gomes PaschoalFujiyama, Roberto Tetsuo
This study describes the Taguchi optimization process applied to optimize drilling parameters for glass fiber reinforced composite (GFRC) material. The machining process is analyzed in relation to process parameters using analysis of variance (ANOVA). The characteristics assessed for both the drilling and the specimen include speed, feed rate, drill size, and specimen thickness. The commercial software program MINITAB14 was used to collect and analyze the measured results. Cutting force and torque during drilling are examined in relation to these parameters using an orthogonal array and a signal-to-noise ratio. The primary goal is to identify the critical elements and combinations of elements that impact the machining process to achieve minimal cutting thrust and torque, based on the evaluation of the Taguchi technique.
Raja, RosariJannet, SabithaKandavalli, Sumanth Ratna
Hybrid reinforcement-made polypropylene (PP) composites are beneficial over monolithic PP and utilized for various engineering and non-engineering applications. The present investigation of PP hybrid composites is developed with 10 percentages of weight (wt%) of E-glass fiber embedded with 0–6 wt% of silicon carbide via compression technique associated with hot press. E-glass fiber and SiC influencing wear rate, tensile strength, and microhardness behavior of PP and its composites are experimentally investigated. The peak loading of SiC as 6 wt% into PP/10 wt% E-glass fiber is recorded as better wear resistance (0.021 mm3/m), maximum tensile strength value (54.9 MPa), and highest hardness (68 HV). Moreover, the investigation results of hybrid PP composite are better resistance to wear and hiked tensile and hardness behavior compared to monolithic PP. This PP/10 wt% E-glass fiber/6 wt% of SiC hybrid composite is adopted for high-strength to lightweight sports goods applications.
Venkatesh, R.
Shipbuilders didn’t have the option of fiberglass when the nonprofit American Bureau of Shipping (ABS) was established 160 years ago to help safeguard life and property on the seas. Fortunately, technology to help better ensure the safety of ocean vessels has also come a long way in that time, in part because people have become a spacefaring species.
Anode-free sodium metal batteries (AFSMBs) with initial zero sodium anodes are promising energy-storage devices to achieve high energy density and low cost. The morphology and reversibility of sodium controls the cycling lifespan of the AFSMBs, which is directly affected by the separator. Here, we compared the sodium deposition and corresponding electrochemical behaviors under the influence of three commercial separators, which were Celgard 2500, Al2O3-coated PP separator and glass fiber (denoting as 2500, C-PP and GF). Firstly, the reversibility of sodium plating/stripping was tested using half-cells, where coulombic efficiencies were stable at ~99.89% for C-PP and GF compare to 99.65% for 2500, indicating more dead sodium were formed for 2500. Then, the morphologies of deposited sodium were compared using optical microscopy. Compared to inhomogeneous sodium growth under 2500, C-PP obtained more flatter sodium layer with less height difference, attributing to the high mechanical strength of Al2O3 layer. Differently, we discovered that sodium was grown into pores in GF to form sodium particles with large active surface, which contacts with sufficient electrolytes and could be reversibly stripped. The reversibility of the sodium in GF were further verified using in situ X-ray diffraction tests. Accordingly, cycling performance of AFSMBs were improved using C-PP and GF, where capacity retention after 120 cycles were 56.9%, 61.6% and 69.2% for 2500, C-PP and GF, respectively. Moreover, the AFSMB using 2 mAh cm-2 Na[Ni1/3Fe1/3Mn1/3]O2 as cathode with GF exhibiting excellent capacity of 117.61 mAh g-1 under high current density of 1 C. Subsequently, in situ EIS tests after/during charging/discharging process were further conducted to illustrate the enhancement of rate and cycling performance. This work demonstrates the effect of separators on the sodium deposition for higher irreversibility and stability, which could also offer insights for developing advanced separators to achieve high performance AFSMBs.
Qin, NanJin, LimingZheng, Jim P.
Today, almost all passenger vehicles are equipped with Mobile Air Conditioning (MAC) systems to provide thermal comfort to occupants. To enhance cabin cooling down rate, two approaches are possible viz. increasing the MAC system capacity or reducing heat ingress into the vehicle cabin. The first approach is likely to have a negative impact on energy efficiency. The latter approach considers the deployment of alternate passive cabin cooling technologies. Among these, the deployment of uniquely developed coatings on metal, plastic and glass surfaces of the cabin is one option. The assessment of such coatings is usually done only at severe ambient conditions (>40°C), which may not be sufficient. These coatings need to be validated across all climatic seasons of the year, for assessing their effectiveness on passenger thermal comfort. The current work along with simulation studies, takes into account additional parameters such as the ‘feeling of hotness’ when one enters a hot-soaked cabin of a typical car not parked under the shade. Further, customer touch point surface temperatures, along with a definition of their acceptance criteria based on thermal comfort considerations, have also been examined in this work. The proposed new and novel process consists of, defining a physical validation methodology comprising of both, objective and subjective assessments on two vehicles, viz. baseline vehicle without coating and proposed vehicle with coating on multiple surfaces. The objective assessments include a set of DoEs on both the vehicles in controlled ambient conditions in a Climatic Chamber, followed by actual real-world vehicle drives and DoEs on the road. The assessment of deterioration with dust application on the coated surfaces and sensitivity analysis with the removal of the proposed coating on some of the surfaces is also examined. Finally, a jury of experts subjectively assessed the effectiveness of the coating and ranked the, ‘critical to thermal comfort’ parameters, on a ten-point scale. This novel methodology enables the objective and subjective assessment of a proposed coating and analysis of gaps with respect to target requirements; the primary objective being to arrive at a holistic decision on implementation for series production.
Deshmukh, GaneshKulkarni, Shridhar DilipraoVarma, MohitJaybhay, SambhajiKapoor, SangeetTilekar, Pravin
This SAE Aerospace Recommended Practice (ARP) covers the requirements for the types of glass to be utilized in the fabrication of cover glasses and lighting wedges used in aerospace instruments. It defines the maximum extent of physical defects and recommends standard methods of inspection and evaluation. Definitions of terminology used in this document are covered in 2.2.
A-20A Crew Station Lighting
Unlike glass, which is infinitely recyclable, plastic recycling is challenging and expensive because of the material’s complex molecular structure designed for specific needs. New research from the lab of Giannis Mpourmpakis, Associate Professor of Chemical and Petroleum Engineering at the University of Pittsburgh, focuses on optimizing a promising technology called pyrolysis, which can chemically recycle waste plastics into more valuable chemicals.
Despite their many similarities, natural fibers have superior mechanical properties to synthetic fibers, including higher ultimate strength, greater elongation, resistance to ethering, biodegradability, lightweight, and fewer toxications. The mechanical characteristics of several matrices reinforced with synthetic and hemp fibers were examined in the current paper. We made the various hemp composites using vinyl ester, cellulose acetate (CA), treated CA, and GFRP (glass fiber-reinforced polymer) with CA. Composites were examined for mechanical characteristics such as tensile, flexural, impact, and hardness. Composites have a density of 1.19 g/cm3. Hemp with vinyl ester has higher tensile strength and flexural properties than other composites, but in impact, GFRP with CA has more impact strength of nearly 400 J/m, so for making eco-friendly biocomposite for lightweight structural applications.
Vinoth Kumar, K.Karthick, K.Balasubramanian, M.Chidhamparam, R.S.Jones, S.
Thermo-mechanical fatigue and natural aging due to environmental conditions are challenging to simulate in an actual test with advanced fiber-reinforced composites, where their fatigue and aging behavior are little understood. Predictive modeling of these processes is challenging. Thermal cyclic tests take a prohibitively long time, although the strain rate effect can be scaled well for accelerating the mechanical stress cycles. Glass fabric composites have important applications in pipes, aircraft, and spacecraft structures, including microwave transparent structures, impact-resistant parts of the wing, fuselage deck and many other load-bearing structures. Often additional additively manufactured features and coatings on glass fabric composites are employed for thermal and anti-corrosion insulations. In this paper, we employ a thermo-mechanical fatigue model based on an accelerated fatigue test and life prediction under hot-to-cold cycles. Thermo-mechanical strain-controlled stress evolution is modeled and tested for fitting fatigue model parameters over thermal cycles under different creep stresses. The model accounts for damage mechanics-based treatment of stiffness degradation up to a limiting inelastic strain up to endurance limit stress, and strength degradation in the process of damage to crack initiation. The strain evolution and stiffness degradation are monitored, and fatigue strength degradation behavior is predicted using the constitutive model. A scheme for remaining user life (RUL) prediction is developed and the scheme is validated using different thermo-mechanical cycles as compared to the data used for fitting the constitutive model parameters. This study limits the fatigue damage to crack initiation in simple flexure and temperature cycles for specific micro-damage coalescence to interlaminar fracture. To generalize the life prediction methodology, a scheme based on finite element stress analysis-based progressive damage methodology is employed, which can be employed for complex composite structures involving different complex damage mechanisms and final failure modes.
Kancherla, Kishore BabuB S, DakshayiniRaju, BenjaminRoy Mahapatra, Debiprosad
A new approach has allowed researchers at Aalto University to design a kind of metamaterial that has so far been beyond the reach of existing technologies. Unlike natural materials, metamaterials and metasurfaces can be tailored to have specific electromagnetic properties, which means scientists can create materials with features desirable for industrial applications.
In this paper, experimental studies were conducted to examine the mechanical behavior of a polymer composite material called polyamide with glass fiber (PA6-GF), which was fabricated using the three-dimensional (3D) fusion deposition modeling (FDM) technique. FDM is one of the most well-liked low-cost 3D printing techniques for facilitating the adhesion and hot melting of thermoplastic materials. PA6 exhibits an exceptionally significant overall performance in the families of engineering thermoplastic polymer materials. By using twin-screw extrusion, a PA6-GF mixed particles made of PA6 and 20% glass fiber was produced as filament. Based on literature review, the samples have been fabricated for tensile, hardness, and flexural with different layer thickness of 0.08 mm, 0.16 mm, and 0.24 mm, respectively. The composite PA6-GF behavior is characterized through an experimental test employing a variety of test samples made in the x and z axes. The mechanical and physical characteristics of PA6-GF polymer were examined using tensile, flexural, and impact tests. The best outcomes were obtained for specimens printed with 0.08 mm lower value of layer height, which had a greater impact on all mechanical performance. The replacement of traditional materials was suggested with this high-strength printed samples in industrial application products.
Sivanesh, A. R.Soundararajan, R.Natrayan, M.Nallasivam, J. D.Santhosh, R.
The current battery carrier for commercial vehicles is made of steel and is designed to hold two batteries weighing approximately 80 kg to 100 kg. However, this battery carrier faces several issues including corrosion, chemical reactivity, high maintenance requirements and its heavy weight. To tackle these challenges, a fiber-reinforced composite battery carrier is designed and developed specifically for commercial vehicles. The objective is to identify a solution that can meet the performance requirements of both static and dynamic loading, thereby reducing the overall weight. The proposed composite battery carrier offers a lightweight design, requires minimal maintenance, possesses high tensile strength and stiffness and is corrosion and chemical resistant. Furthermore, it provides the flexibility to integrate battery cover locking arrangements for added convenience and security. The structure of the composite battery carrier comprises a continuous glass fiber reinforced composite with a polyester resin matrix. Detailed finite element analysis is conducted to ensure optimal performance under static and dynamic conditions. Altair Hypermesh is used for pre-processing, while the Altair OptiStruct solver is utilized for structural analysis, lay-up design and optimization. The laminate design incorporates an orthotropic material model, considering various lay-up configurations. Upon finalizing the lay-up design, a prototype model is manufactured. The manufacturing process employs the Vacuum Bagging Process. As a result, the composite battery carrier achieves a substantial weight reduction of approximately 30% to 50% compared to a steel battery carrier.
Srivastava, SanjaySonkusare, Shailesh
FMVSS No. 205, “Glazing Materials,” uses impact test methods specified in ANSI/SAE Z26.1-1996. NHTSA’s Vehicle Research and Test Center initiated research to evaluate a subset of test methods from ANSI Z26.1-1996 including the 227 gram ball and shot bag impact tests, and the fracture test. Additional research was completed to learn about potential changes to tempered glass strength due to the ceramic paint area (CPA), and to compare the performance of twelve by twelve inch flat samples and full-size production parts. Glass evaluated included tempered rear quarter, sunroof, and backlight glazing. Samples with a paint edge were compared to samples without paint, and to production parts with and without paint in equivalent impact tests. A modified shot bag with stiffened sidewalls was compared to the ANSI standard shot bag. The fracture test comparison included evaluating the ANSI Z26.1 impact location and ECE R43 impact location. Over 900 tests covering the various test conditions outlined above were completed. High-speed video was recorded for each test to capture break initiation and propagation. Overall trends showed a decrease in glazing strength due to the CPA when impacted with the 227 gm ball. The modified shot bag concentrated the impact force, resulting in more glass breakages than with the ANSI bag. ECE R43 fracture test location produced larger pieces than the ANSI fracture location. Results of this study may be used to help determine if the tests in ECE R43 and ANSI/SAE Z26.1-1996 can be harmonized to reduce testing burden, and also if the effect of the ceramic paint on glazing performance could be considered in evaluating glazing performance.
Rains, Corinn
Recently, the environmental temperature of vehicles is changing due to the electrification of vehicles and improved internal combustion engine system to reduce carbon emissions. However, mechanical properties of plastic materials change very sensitively to environmental temperature changes, and mechanical properties decrease when exposed to high temperatures. Therefore, it is important to estimate lifespan estimation of plastic parts according to temperature changes. In this paper, reliability analysis process to estimate the maximum service temperature of plastic parts was developed using aging data of material properties, environmental condition data of automotive parts, and field driving condition data. Changes in the mechanical properties of plastic materials such as glass fiber reinforced polyamide materials were tested. The environmental exposure temperature of the vehicle and parts was measured, and the general driving pattern of the vehicle was analyzed. Weibull aging model and Arrhenius physics model was applied for lifespan estimation of materials. The damage rate theory was applied to obtain the sum of damage rates in various temperature conditions since automobiles are exposed to various temperature conditions. The damage rate according to the temperature and time exposed to the environment was calculated with lifespan estimation results of materials and environment conditions of plastic parts, then the maximum service temperature that can satisfy the warranty period of the product was predicted. As case studies, the maximum service temperature of the air intake manifold, the bracket part that support the motor in EVs or the transmission in internal combustion engines with glass fiber reinforced polyamide was predicted with reliability-based maximum service temperature estimation method.
Youn, Jee YoungChung, Min GyunAhn, Hyo Sang
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