Browse Topic: Lightweight materials

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Topology Optimization of Lightweight for Frame Structure of Deep-Sea Mining Vehicle2026-99-01307/31/2026
In order to improve the self-sufficiency rate of key mineral resources in China, it is necessary to develop and research deep-sea mining vehicles to improve the mining capacity of seabed mineral resources. The deep-sea mining vehicle is a heavy-duty underwater robot, and its main frame structure, as a critical component, must be designed to be lightweight to improve payload capacity and mining efficiency. This paper first conducted static analysis for the initial main frame structure. Finite element analysis results indicate that the initial structure fails to meet the strength requirements for lifting and recovery operations. The power index penalty factor was introduced into the topology optimization, which was based on the variable density method. The topology optimization objective was set to minimize structural compliance, with the maximum element stress and volume fraction used as constraints. The optimization process finally obtained the optimal material distribution. According to the results of topology optimization and space requirements of the installed equipment on the deep-sea mining vehicle, the new frame structure of the mining vehicle was re-established in the secondary modelling. According to the results of the analysis, the weight of the frame structure was reduced by 2.9%, and at the same time, the maximum stress was reduced by 57.2%, the maximum displacement was reduced by 47.2%, and the first-order natural frequency was increased by 54%. The strength and stiffness of the frame structure were greatly improved.
Tao, Yichun, Yang, Mingyu
Discussion on Methods for Studying Material Fatigue Life: Taking Aluminum Alloy as An Example2026-99-01217/31/2026
Fatigue design is a key common quality technology for improving the quality control capability of China’s automotive products. The fatigue of materials is a multi-scale damage evolution process. Characterizing and processing the large number of three-dimensional defects inside the material, which have different shapes and distributions, and predicting the material’s lifespan based on the cross-scale damage evolution mechanism, is one of the key technologies for fatigue optimization design. This paper discusses the research methods for the fatigue life of aluminum alloy materials. Firstly, based on the staged fatigue damage experiments, the three-dimensional defect features are obtained through CT scanning and reconstruction, and a defect characterization and processing method based on k-d tree and multi-scale feature pyramid is established to accurately represent the topological and geometric relationships of non-uniformly distributed three-dimensional defects. Secondly, a mathematical model for the evolution of micro-damage and macro-cracks is constructed, and the cross-scale transformation of defects is achieved through hierarchical and recursive methods, revealing the cross-scale evolution mechanism of fatigue damage in aluminum alloy materials. Finally, a remaining life prediction model based on defect information and feature weights is established through the support vector regression algorithm (SVR). This research method can provide technical support for the fatigue life optimization design application of lightweight materials such as aluminum alloys.
Zhang, Liangxia, Niu, Zhijun, Cheng, Fangfang, Chen, Hao, Yang, Yali
Research on Explicit Topology Construction and Shape Optimization via Hole Deformation2026-99-18367/17/2026
Topology optimization provides innovative solutions for lightweight structural design by rationally arranging material distribution. It enhances structural performance while reducing material consumption and structural weight, thereby significantly lowering production and operational costs and generating enormous economic benefits. In the development of topology optimization, the density-based method has gained widespread adoption due to its easy-to-understand principles. However, this method still faces the following challenges when applied to engineering applications. First, the geometric models generated by topology optimization lack explicit parameter descriptions, leading to data interaction barriers with Computer Aided Design (CAD) systems. Second, due to element discretization and density penalty mechanisms, structural boundaries exhibit rough and blurred characteristics. These problems severely constrain the iterative efficiency of structural design and manufacturing feasibility. To address these issues, this paper proposes a strategy for geometric reconstruction and shape optimization of topology optimization results. The reconstruction process begins with extracting isolines from the density field as a set of contour points. These points are subsequently interpolated with B-spline curves to explicitly represent the geometric boundaries. Shape optimization is then carried out by adjusting the positions of the B-spline control points. Compared to post-processing methods based on graphics techniques for topology optimization, which ignore the volume constraint and performance loss, the structures reconstructed in this paper exhibits the following advantages: structural boundaries are smoothed and characterized with explicit parameters, reducing performance loss caused by geometric reconstruction while satisfying volume constraints. This paper successfully establishes compatibility between topology optimization and CAD systems, facilitating the transition from conceptual design to manufacturing.
Tang, Yuting, Li, Yu, Luo, Jiaxiang, Chen, Junwei, Zhou, Weien, Yao, Wen
Drilling Studies on Sustainable Lightweight Hybrid Polymer Matrix High-Performance Nanocomposites2026-26-07326/1/2026
Worldwide, engineers are exploring the possibility of using polymer composites in their quest for lightweight materials. In this study, injection moulding was used to develop a biodegradable polymer PLA composite containing 20 wt.% vetiver fibers (VFs) and 2 wt.% nano-silica (nSiO2) obtained from pearl millet, which is sustainable. Materials need machining as secondary operation that required joining. Desirability analysis was used to examine and optimize machining (drilling) studies that were designed with Taguchi's design (L9 orthogonal array). Surface roughness (SR) and delamination factor (Fd) were taken as outputs, while spindle speed (SS), feed rate (FR), and drill diameter (DD) were the inputs. Drilling studies were performed on a single vertical machining center (VMC). ANOVA identifies that the FR had the most decisive influence on SR (F=559.24, p=0.001785), followed by DD and SS. FR is the dominant contributor to Fd (F=379, p=0.00263), followed by SS and DD. At low SS and high FR, excessive thrust and heat cause fiber-matrix tearing and poor hole finish. Higher SS softens the PLA matrix, improving surface quality. Fd decreases with increasing SS, whereas it rises with extreme FR and DD due to elevated thrust and matrix cracking. The optimized parameters SS of 3000 rpm, FR of 15 mm/min, and DD of 6 mm achieved a maximum combined desirability of 1. A non-traditional meta-heuristic technique, the frog leaping algorithm (FLA), is adopted to optimize the inputs based on the developed regression model. FLA also provides the identical optimal condition as the desirability function, predicting the outputs SR=2.2195 μm and Fd=1.0383, which are very close.
Senthilkumar, N.
Predictive Model and Analysis of the Resultant Force in the Dry Machining of Mg-4Zn/Si 3 N 4 Nanocomposites2026-26-07626/1/2026
The development of lightweight materials for use in aerospace and automotive applications is extremely significant. Magnesium (Mg)-based alloys and composites are good candidate materials from the perspective of low density, good specific strength, and abundance. The Mg-4Zn alloy is one such alloy, which is a lightweight, biocompatible, and eco-friendly Mg-based alloy. In spite of these advantages, there is a strong need and scope to improve its wear resistance and mechanical properties. Mg-4Zn nanocomposites with Si3N4 reinforcements (a biocompatible bioceramic) are hypothesized to possess superior properties. Microstructural analysis of the vacuum stir-cast nanocomposites confirms grain refinement and a consequent increase in microhardness with an increase in Si3N4 reinforcement wt.%. The addition of Si3N4 reinforcement to improve the properties of the Mg-4Zn alloy could introduce challenges in machining. To make products from the nanocomposites, machining them with minimal subsurface defects with minimal energy consumption under sustainable conditions is necessary. The resultant machining force (Fr) is a good indicator of subsurface quality and energy consumption in machining. To investigate the effect of reinforcement wt.% and machining parameters on the resultant machining force, dry turning experiments on the vacuum stir-cast Mg-4Zn/Si3N4 nanocomposites were carried out based on the response surface methodology-based Box-Behnken design. It is observed that the regression model for Fr is influenced by the reinforcement wt.%, cutting speed, feed rate, and depth of cut and also their squares and their mutual interactions. Increase in microhardness, variation in porosity, thermal softening, and strain hardening contribute to the variation in Fr. Minimal Fr and hence better subsurface quality and lower energy consumption are obtained at mid values of Si3N4 reinforcement wt.% and cutting speed and low values of feed rate and depth of cut. The developed model is an excellent fit, with R2 and adjusted R2 values of 0.9907 and 0.9799, respectively.
N, Anand, Shaju, Tony M, G, Nagamalleswara Rao, D, Bijulal, K, Jayaprakash Reddy, K, Vijayan, Chaman, Joji J
Investigation of Metallurgical and Mechanical Behaviors of AA6061-AA2017 Joints Produced by Single- and Double-Pass Friction Stir Welding: Influence of Base Material Position and Post-Weld Shot Peening Technique05-19-04-00264/13/2026
The growing demand for lightweight, high-strength materials in marine and aerospace structures has promoted the use of friction stir welding (FSW) for welding dissimilar aluminum alloys. However, tensile residual stresses and microstructural heterogeneities often degrade weld integrity. This study investigates the combined impact of base material positioning, single- and double-pass FSW, and post-weld shot peening (SP) on the metallurgical and mechanical properties of AA6061–AA2017 joints. Five welding configurations were examined to evaluate how varying base material positions on the advancing and retreating sides affect material flow and mechanical behavior. Post-weld SP effectively presented compressive residual stresses, reduced surface defects, and refined surface grains. The average grain size in the stir zone was reduced from 5.2 μm (single-pass) to 2.0 μm (double-pass U-turn) after SP, confirming significant grain refinement through dynamic recrystallization. Mechanical testing revealed that double-pass FSW with opposite weld direction (U-turn) followed by SP achieved the highest performance, with ultimate tensile strength (UTS) improving from 246 MPa to 289 MPa (≈17% increase) and tensile elongation rising from 8.78% to 9.41%. Microhardness in the heat-affected zone improved up to 127 VHN, countering thermal softening effects. The synergistic effect of double-pass welding and SP enhanced homogeneity, fatigue resistance, and surface integrity. The results establish SP as an efficient post-FSW treatment for dissimilar aluminum joints, offering quantifiable improvements in strength and ductility, making the process highly suitable for demanding marine and aerospace structural applications.
Nukathoti, Raja Sekhar, Battina, N. Malleswara Rao, Vanthala, Varaha Siva Prasad, Chirala, Hari Krishna, Maloth, Balu
Multi-Material Topology Optimization Using Difference-Based Equivalent Static Load Method2026-01-01734/7/2026
Topology optimization (TO) has become a powerful tool for generating lightweight structural designs. TO has been widely applied to linear static problems, where analytical sensitivities are easy to obtain. However, crashworthiness design requires nonlinear dynamic analysis, for which analytical sensitivities are generally not available. To extend TO into crash problems, approximation methods such as the Equivalent Static Load (ESL) method have been developed. ESL replaces the nonlinear problem with a series of linear static subproblems, ensuring that the displacement fields match at certain time steps. These subproblems can then be efficiently solved using standard TO techniques. A key limitation of ESL is that it relies on the initial mesh for all subproblems, which reduces accuracy for highly nonlinear crash responses. To address this, Triller proposed the difference-based ESL (DiESL) method, which updates the mesh in each subproblem to the deformed configuration, therefore improving approximation accuracy. However, existing DiESL implementations are restricted to single-material topology optimization (SMTO), where elements can be either solid or void. In contrast, multi-material topology optimization (MMTO) allows multiple material candidates per element, offering greater design freedom and the potential for better solutions. For crashworthiness applications, MMTO can leverage low-density materials (e.g., aluminum or magnesium) to form thick members that resist buckling, while using high-strength, high-density materials (e.g., steel) in critical stress regions to prevent yielding. By combining MMTO with DiESL, nonlinear crash performance can be further improved, offering a promising framework for lightweight and crashworthy structural design.
Huang, Yuhao, Kim, Il Yong
Beyond PFAS: Unlocking the Potential of R290 and R744 for EV Efficiency2026-01-01274/7/2026
The anticipated PFAS ban in the US by 2029 has created a need to evaluate alternative refrigerant solutions for automotive thermal management systems. This work compares three candidates—Propane (R290), Carbon Dioxide (R744), and R1234yf—through system-level testing and demonstration projects. R1234yf remains the current industry baseline. Test results show that Propane (R290) delivers comparable efficiency while offering a significantly lower global warming potential. However, its flammability presents integration challenges, not present with R1234yf or R744. CO₂ (R744) demonstrated promising performance as well. To address safety concerns with Propane, AVL developed mitigation measures including rapid leak detection, robust containment strategies, and optimized circuit layouts designed to reduce ignition risks. These countermeasures were validated in practice through the European Commission’s QUIET project. Within this program, a Honda B-segment electric vehicle was equipped with a Propane-based heat pump, thermal storage, infrared cabin heating, and lightweight materials. Testing under real-world conditions showed a 25% increase in driving range in cold conditions while maintaining passenger comfort [25,25]. An AI-based control strategy further improved system efficiency by coordinating thermal and energy management. The findings demonstrate that Propane can be a feasible replacement refrigerant for electric vehicle applications if appropriate safety measures are implemented. CO₂ also remains a strong candidate, offering a cost-effective and PFAS-compliant solution. Together, these results contribute to the evaluation of sustainable refrigerants and provide guidance for future thermal system development in the automotive sector.
bires, Michael, Possegger, Jonathan
High Strain Rate Behaviors of Fiber Reinforced Composites in Principal and Off-Axis Directions2026-01-01754/7/2026
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, Prashant, Deb, Anindya, Barui, Ananya, Zhu, Feng
Environmental Impact Analysis of a Multi-Material Body Shell15-19-01-00032/28/2026
In recent times, energy conservation and environmental protection have attracted more and more attention. This research presents a comparative study on the quantitative analysis and comprehensive ranking of the cradle-to-grave environmental benefits of a multi-material body shell across 18 countries. For quantitative analysis of the cradle-to-grave environmental impact of the body shell, life cycle assessment (LCA) was adopted to assess the process of interactions between the environment and human activity. For a comprehensive ranking of the environmental impacts across 18 nations, two modified techniques were used for order preferences by similarity to the ideal solution (TOPSIS) methods, which are improved by the fuzzy analytic hierarchy process (FAHP) and entropy method (EM). The outcomes from these three methodologies; FAHP&EM-TOPSIS, FAHP-TOPSIS, and conventional TOPSIS revealed that the comprehensive environmental benefit rankings of TOPSIS are highly different from the two improved TOPSIS methods, which shows the superiority of modified TOPSIS. The common results of the three measurement methodologies were that New Zealand has the best environmental benefit and Mexico’s environmental performance is the worst. Based on the two modified TOPSIS methods used in this study, the comprehensive environmental benefit resulting from the multi-material body shell in various countries can be compared and analyzed accurately and subjectively. Lastly, the obtained results underscore the illumination, usefulness, and practicality of the modified TOPSIS.
Li, Shuhua, Wu, Zongyang, Ji, Xiaoyuan, Tang, Zheng, Wu, Bofu, Rokhsun, Hossain Rahman
Durability Validation of Full Vehicle Structures Using Strain Correlation and RLDA-Based Simulations2026-26-05231/16/2026
Durability validation of full vehicle structures is crucial to ensure long-term performance and structural integrity under real-world loading conditions. Physical test strain and finite element (FE) strain correlation is vital for accurate fatigue damage predictions. During torture track testing of the prototype vehicle, wheel center loads were measured using wheel force transducers (WFTs). In same prototype strain time histories were recorded at critical structural locations using strain gauges. Preliminary FE analysis was carried out to find out critical stress locations, which provided the basis for placement of strain gauges. Measured loads at wheel centers were then used in Multi Body Dynamics (MBD) simulations to calculate the loads at all suspension mount points on BIW. Using the loads at hard points transient analyses were performed to find out structural stress response. Strain outputs from the FE model were compared with physical measurements. Insights gained from these comparisons were used to update the model to achieve better correlation with test data. The findings of this paper establish a robust methodology for improving vehicle durability assessments by enhancing confidence in fatigue life predictions and structural performance. By integrating physical testing and FE simulations, this approach ensures accurate strain correlation and effective validation of long-term performance. It also provides a scalable framework for validating structural changes, supporting lightweight material integration, and enabling Value Analysis/Value Engineering (VAVE) initiatives to optimize cost-effectiveness and performance. This methodology strengthens simulation-driven durability development, offering valuable insights for future vehicle programs.
Jaju, Mayur, Dokhale, Sandeep, Gadre, Nilesh, Patil, Sanjay
Development of a Lightweight Front-End Structure Using Injection Molding Technology2026-26-03041/16/2026
This paper focuses on the development of a lightweight, functionally integrated Front-End Structure (FES) using plastic-metal hybrid injection molding technology. The objective is to achieve modularization, part consolidation, weight and cost reduction. The proposed design integrates multiple components into a single module which makes assembly faster and easier. A mounting strategy with fixation features was added into the structure, which effectively supports various components and sub-assemblies. Component-level Finite Element Analysis (FEA) was carried out which includes static strength analysis, bending and torsional stiffness analysis, modal analysis as well as latch pull test to achieve required structural strength. Ribbing structures were designed and optimized based on FEA result to provide the necessary strength and stiffness to the structure within the minimum weight. Moldflow analysis was carried out to evaluate manufacturability with focusing on gate design, minimizing warpage, and flow balance. Based on Moldflow analysis, necessary design corrections were carried out before tool development for defect-free molding. After validating all performance criteria, the part was manufactured using injection molding process. Compared to conventional sheet metal structures, the thermoplastic FEM achieved an approximate 50% weight reduction while maintaining structural integrity.
Srivastava, Sanjay, Thakoor, Shruti Ghanshyam, Sonkusare, Shailesh
Response Analysis and Optimization of a Lightweight Seat Ring under Airborne Landing Impact2025-99-041112/10/2025
In order to meet the high lightweight and transmission accuracy requirements of a certain airborne system, the seat ring bearing adopts a lightweight material 4-point contact ball slewing bearing. However, the non-linear contact of a large number of balls during the working process of the seat ring makes simulation difficult, and ball damage often occurs in previous experiments. Based on the bearing capacity of the shaft, the influence of uneven load transmission of the ball on the response was considered. The response of the bearing under shooting and airdrop landing impact loads was calculated and analyzed using multi rigid body and finite element methods, respectively. The results indicate that under the impact load, the stress on the ball has exceeded the yield limit of the material, resulting in irreversible plastic deformation. The plastic deformation morphology is basically consistent with the damage morphology of the test ball, which verifies the accuracy of the simulation model. In response to the issue of insufficient ball strength, the seat ring and ball were optimized and designed. After improvement, the structural stress level was significantly reduced and remained within the elastic range of the material, indicating the effectiveness of the optimization and improvement measures.
Zhang, Taiping, Ning, Bianfang, Wang, Huating, Fan, He
Altair lauds lightweight-engineering efforts25TOFHP12_0712/1/2025
Winners of the 13th edition of the Altair Enlighten Awards, presented in association with the Center for Automotive Research, were recognized during a ceremony at the CAR Management Briefing Seminars in Detroit. The awards not only acknowledged the automotive and commercial vehicle industries' best initiatives to reduce vehicle weight and meet emissions targets, but also considered other parameters such as cost reduction, part count reduction and applicability to other vehicle programs. “Starting in the 2000s, the automotive industry wasn't really that interested in optimization. Weight was an outcome of achieving performance. Seeing the rise of these digital technologies over two decades has been such a thrill,” Royston Jones, CTO of Altair Product Design and senior VP for automotive, said to kick off the event. “I'd say now we're really through the gate, particularly over the last five years where globally there's such pressure to develop products quickly. AI has really helped with technology such as optimization, so I think it's only going to accelerate, it's going to get smarter. This is such an exciting time to be in this digital space.”
Gehm, Ryan
Additively Manufactured Aluminum-Lithium Alloys—Advances, Challenges, and Future Directions2025-01-507611/18/2025
Aluminum-lithium alloys are extensively used across various industries due to their exceptional strength-to-weight ratio, excellent fatigue/corrosion resistance and good thermal stability. These attributes, combined with improved weldability and ease of fabrication, make them ideal for lightweight engineering applications in sectors such as aerospace, automotive, and defense. Additive manufacturing (AM) offers unique opportunities to fully leverage the potential of aluminum-lithium alloys by enabling the fabrication of complex geometries, minimizing material waste, and supporting on-demand production. This paper explores the significance of lightweight materials, traces the evolution of aluminum-lithium alloys and provides a comprehensive overview of their AM. It discusses the properties and real-world applications of these alloys and examines various AM techniques employed in their processing. Key advancements in the AM of aluminum-lithium alloys are reviewed, including novel alloy formulations, development of high-lithium-content variants, microstructural and mechanical property enhancements through heat treatment, defect mitigation strategies, and surface treatment methods for performance improvement. Challenges associated with the AM of aluminum-lithium alloys are also addressed. The paper concludes by outlining future research directions and technological developments aimed at advancing AM processes for next-generation lightweight engineering solutions.
Santhana Babu, A.V., Antony Benson, B., Danusha, M.
Durable Aluminum Alloys for Brake Disc and Rotor Applications2025-01-03589/15/2025
Lightweight materials are essential in reducing the overall weight and improving the efficiency and performance of ICE and electric vehicles. The use of aluminum alloys is critical in transitioning to a more energy sustainable and environmentally friendly future. The accessible combinations of high modulus to density and strength to weight ratios, as well as their excellent thermal conductivity, make them an ideal solution for overall weight reduction in vehicles, thereby improving fuel efficiency and reducing emissions. Aluminum alloys with high strength and lifetime thermal stability have been industrialized for usage in brake rotor applications. Amongst the most used aluminum alloys with high thermal stability are 2618-T8 and 4032-T6 for use in aerospace and automotive industries, respectively. However, when it comes to prolonging the life of a product at temperatures that exceed 200°C, the properties of these alloys will quickly degrade within the first 300 hours of exposure. Therefore, a new generation of Al-Cu-Mg alloys was developed to further optimize properties and to provide the maximum strength at elevated temperatures with the highest thermal conductivity. Adequate testing exposing them to temperatures up to 300°C for an extended period of time showed that they do not demonstrate significant loss in mechanical strength. In addition, simulations to predict the aluminum strength loss during braking were generated and results are cross compared to cast iron, SS and 304L.
Duchaussoy, Amandine, Lorenzino, Pablo, Franklin, Jack, Tzedaki, Maria
Research on Multi-Material Lightweight of Electric Vehicle Battery Box13-06-02-00136/23/2025
To select appropriate lightweight materials and optimize their integration with battery enclosure components for enhanced performance and weight reduction, this study proposes a material selection strategy driven by mechanical property indices combined with the CRITIC-weighted TOPSIS method. Initially, a decision matrix incorporating bending stiffness indices was established based on the deformation characteristics of battery enclosures, focusing on commonly used metallic materials. The CRITIC-weighted TOPSIS method was employed to standardize data dimensions, determine objective weight coefficients, and calculate relative closeness coefficients for candidate material screening. Subsequently, sensitivity analysis identified critical components significantly influencing operational conditions, followed by integrated material and dimensional optimization to determine the optimal solution. The optimized battery enclosure achieved a weight reduction of 15.56 kg, with a reduction rate of 33.39%, while maintaining compliance with static/dynamic performance requirements and safety standards. This methodology demonstrates effective coordination between material selection and structural optimization in lightweight design applications.
Liu, Junfeng, Kang, Yuanchun
Material Augmentation for Coaxial Propellers of Titan’s Unmanned Airship: Implementation of Advanced Composites for the Propulsive System under Unconventional Loading Conditions with Incorporation of Structural Integrity Examinations2025-28-01672/7/2025
Exploration vehicles on Titan are to be developed with considerations on the atmosphere present, especially the abundance of Nitrogen. This study focuses on identification of optimum materials for the propellers supporting an airship specifically created for Titan exploration. The base airship is designed to accommodate the coaxial propeller. The base of this airship is to be developed with four weather stations for collection of data samples. The stations are installed on inflatable platforms and have storage devices for recording and transmitting data collected by the aerobot. The airship will operate in Titan's atmosphere and atmospheric conditions, focusing on its design and computational analysis of structural effects and fluid dynamics. The Titan aerobot is built with a co-axial 4-blade propeller, horizontal and vertical fins, and a reaction wheel for yaw maneuvers. The co-axial propulsive system is capable of overcoming drag during steady level flight in the Titan atmosphere. Structural parameter research is conducted during the material selection process for the propeller, examining materials from common materials to isotropic and orthotropic composites, metal alloys, and various composites. Two-way coupling fluid structural interaction is the foundation of computational structural analysis, transferring loads from transient flow analysis to the structure. The best performing materials for each scenario are determined based on the combined results for gust loads. By importing the aerodynamic load created from the gust effects, the structural integrity incorporated with material data is determined on the basis of Equivalent stress, strain, strain energy and deformation. From the analysis conducted, it is inferred that the material GY-70 fiber-based composite, belonging to Carbon fiber category, is seen to be providing the most favorable results with comparatively less deformation, hence providing optimum materials for the unconventional conditions provided.
Baskar, Sundhar, Vinayagam, Gopinath, Pisharam, Akhila Ajith, Gnanasekaran, Raj Kumar, Raji, Arul Prakash, Stanislaus Arputharaj, Beena, L, Natrayan, Ganesan, Balaji, Raja, Vijayanandh
Operation of Advanced Flying Wing UAV: Examination of Structural Performance under Aberrant Pressure and Thermal Loading Conditions with Integrated Computational Study2025-28-00602/7/2025
The objective of this research is to present a novel variant of an Unmanned Aerial Vehicle (UAV) with an advanced flying wing configuration capable of detecting and rescuing individuals affected by avalanches. This leads to testing of the UAV, to identify if it can operate efficiently at the intended temperature and atmospheric conditions. Typically, UAVs can operate in a broad spectrum of temperatures. Regions prone to avalanches would experience near-cryogenic temperatures. The notion is investigated and tested in this specific scenario. The chosen location is Siachen, where temperatures can become as low as -25 degree Celsius (°C). It has been proven that a thermal camera aids the UAV to detect the distinct body heat signatures of individuals who are trapped under snow. The selection of wing, propeller, and vertical stabilizer airfoils is guided by standard analytical calculations, while the overall model is developed using 3D EXPERIENCE. The computational tests are conducted using ANSYS Workbench software to determine the aerodynamic forces acting on the flying wing UAV under several conditions, such as maximum maneuvering working conditions, and average forward speed at extremely low thermal conditions. The outcomes of these tests are validated by the experimental testing of a tapered wing in a subsonic wind tunnel. The selection of suitable lightweight material for the low-temperature application is accomplished through the utilization of Fluid structure and thermal interaction analysis where, in addition to pressure load, temperature load has also been imported by using one-way coupling approach to identify the deformation due to the temperature loadings. To conduct a comparative analysis of the results, the displacements, stresses, strains, and strain energies-based conditions characterized by extremely low temperature levels are calculated for different composite materials. According to the comprehensive approach mentioned, the carbon fiber composite families perform much better than other polymer composite families. The carbon fiber derivative GY-70 exhibits superior performance compared to other lightweight materials. Additionally, AS carbon fibre-based composite reacted with less structural outcome under thermal loading conditions.
Veeraperumal Senthil Nathan, Janani Priyadharshini, Pisharam, Akhila Ajith, Sourirajan, Laxana, Baskar, Sundhar, Vinayagam, Gopinath, Stanislaus Arputharaj, Beena, L, Natrayan, Sakthivel, Pradesh, Raja, Vijayanandh
Greenhouse Gas Emissions from Fuel Cell Heavy-Duty Vehicles in China: A Cradle-to-Gate Analysis13-06-03-00182/4/2025
Considered as one of the most promising technology pathways for the transport sector to realize the target of “carbon neutral,” fuel cell vehicles have been seriously discussed in terms of its potential for alleviating environmental burden. Focused on cradle-to-gate (CtG) stage, this article evaluates the environmental impacts of fuel cell heavy-duty vehicles of three size classes and three driving ranges to find the critical components and manufacturing processes in the energy context of China. The findings show that the greenhouse gas (GHG) emissions of the investigated fuel cell heavy-duty vehicle range from 47 ton CO2-eq to 162 ton CO2-eq, with the fuel cell system and hydrogen storage system collectively contributing to 37%–56% of the total. Notably, as the driving range increases, the proportion of GHG emissions stemming from fuel cell-related components also rises. Within the fuel cell system, the catalyst layer and bipolar plate are identified as the components with the most significant impacts, accounting for 62.9% and 32.7%, respectively, of the total GHG emissions from a fuel cell stack. The fundamental materials constituting these components namely, platinum, titanium, and carbon black are thus of considerable significance in the emission profile of the fuel cell stack. For the hydrogen storage system, carbon fiber-reinforced polymer (CFRP) layer stands out as the most important component, constituting 98% of the total GHG emissions. It is suggested that GHG emissions from fuel cell systems and hydrogen storage systems can be effectively curtailed by implementing strategies such as grid decarbonization, reducing Pt loading in catalysts, and enhancing fuel cell power density. Additionally, the potential for GHG emissions reduction in fuel cell heavy-duty vehicles can be reinforced through the adoption of lightweight materials and the integration of low-carbon alternatives into the glider components.
Mu, Zhexuan, Deng, YunFeng, Bai, Fanlong, Zhao, Fuquan, Liu, Zongwei, Hao, Han, Liu, Ming
Advancements in Lightweight Composite Materials for Enhancing the Structural Integrity of Automotive Component2025-01-50051/23/2025
This research was conducted with the aim of exploring the usage of advanced lightweight materials such as aluminum matrix composite and aramid fiber reinforcement polymer for increased structural integrity of the hood of an automotive vehicle. The automotive sector is moving toward lightweight materials because of the need to enhance fuel efficiency, the importance of reducing environmental impact, and the need to ensure safety of new-generation automobiles. While traditional materials such as steel and aluminum might be very rigid and durable, they also add huge weight to the overall vehicle design. Consequently, these vehicles become more fuel inefficient, which could lead to higher emissions and pollution. The two materials chosen for this research are very promising, considering that both are characterized by high specific strength and impact resistance capabilities. The low weight of the materials is also an added bonus. While AMC is manufactured by consolidating aluminum with ceramic or metallic components, AFRP employs aramid fibers in a polymer matrix. The test performed in this research to evaluate the suitability of the two materials for the said purpose include tests on impact resistance, tensile strength, and hardness. The materials were tested concerning the standards of the Charpy test, the universal testing machines, and the Vickers scale. The findings of the test produced differing results concerning the two materials. AMC demonstrated an average impact resistance of 76 kJ/m2, a tensile strength of 402 MPa, and a hardness of 122 HV. AFRP, on the other hand, registered superior values for the said test: an average impact resistance of 153 kJ/m2, a tensile strength of 556 MPa, and a hardness of 122 HV. Consequently, the research concludes that AFRP is the most suitable material for hood design in the automotive industry.
Arvinda Pandian, C.K., Balaji, N., Seeniappan, Kaliappan, Natrayan, L., Maranan, Ramya, Ravi, D.
Letter from the Guest Editors13-05-03-001612/31/2024
Letter from the Guest Editors
Farahani, Saeed, Vargas-Silva, Gustavo, Kazan, Hakan, Moradi, Mahmoud, Medina, Carlos
Effect of TiO 2 & B 4 C on the Mechanical Behavior and Microstructural Properties of Light Weight Hybrid Metal Matrix Composites for Compact Automobile Applications2024-01-520812/10/2024
This Experimental study demonstrates the influence of titanium dioxide (TiO2) and boron carbide (B4C) reinforcements on the mechanical behaviour and microstructural characteristics of lightweight hybrid metal matrix composites (HMMCs) tailored for compact automobile applications. The Aluminium metal matrix composites were synthesized using stir casting technique to ensure uniform dispersion of titanium dioxide (TiO2) and boron carbide (B4C) reinforcements within the aluminium matrix. Characterization techniques such as scanning electron microscopy (SEM) and optical Microscopy, were employed to analyze the microstructural evolution and phase distribution. Mechanical properties such as hardness, tensile strength, and wear resistance were systematically evaluated. The results demonstrated significant enhancements in mechanical performance with 38% increase in tensile strength, 22% increase in impact strength which are attributed to the synergistic effects of TiO2 and B4C. These improvements were correlated with refined grain structures and the formation of stable intermetallic compounds. The optimized HMMCs exhibited a remarkable balance of low density and high strength, making them highly suitable for automotive components requiring weight reduction without any compromise in durability and performance. This research provides valuable insights into the development of high-performance, lightweight materials for the automotive industry.
Jaswin, M. Arockia, Geetha, R., Mathialagan, Saravanan, Suresh, S.
Analyzing the Effect of Silicon Carbide and Flyash Reinforcement on the Phase Morphology and Mechanical Properties of 7075 Aluminum Alloy Produced through Stir-Casting Process2024-28-016512/5/2024
Growing demand for fuel-efficient vehicles and lower CO2 emissions has led to the development of lightweight materials. Aluminum composites are being used to achieve lightweighting to improve performance, efficiency, and sustainability across various industries. The unique properties of aluminum composites make them an attractive choice for researchers and designers looking to optimize their products. Reinforcement materials play a vital role in the development of these composites, acting as barriers to dislocation movement within the aluminum matrix. This effectively strengthens the material and prevents deformation under load, resulting in increased tensile strength and fatigue resistance. Additionally, aluminum composites exhibit improved thermal and electrical conductivity, making them suitable for automotive applications. In this study, metal matrix composites (MMCs) of aluminum 7075 alloys were developed using silicon carbide (SiC) and flyash as reinforcements. Three different compositions were cast using the stir casting technique: 10% fly ash, 10% SiC, and 5% SiC plus 5% fly ash. A detailed characterization of these composites was conducted using Scanning electron microscopy coupled with Energy-Dispersive X-ray spectroscopy, focusing on the metallurgical characteristics of the materials. This analysis revealed the distribution of eutectic phases, primary aluminum matrix, intermetallic compounds, chemical zonation, and precipitates at grain boundaries, resulting in improved strength, hardness, and wear resistance. The results showed that the flyash composition exhibited increased wear resistance due to the formation of complex phases, while the SiC composition showed improvements in tensile strength and hardness.
Manwatkar, Asmita Ashok, Santosh Jambhale, Medha, Mahagaonkar, Nitin, Sharma, Dipesh
Advancing Automotive Light-weighting: Material–Process–Microstructure–Performance (MP2) Relationships of Supercritical Foam Injection of PP–Graphene Nanocomposite Foams and Over-molding13-05-03-001910/23/2024
Vehicle light-weighting constitutes a critical component in the automotive sector’s drive to improve fuel economy and reduce greenhouse gas emissions. Among the various options for lightweight materials, thermoplastic foams are distinguished by their durability, low weight, and environmental sustainability. This study explores the manufacturing of novel graphene-filled polypropylene (PP) foam, employing supercritical nitrogen as an eco-friendly substitute instead of conventional chemical foaming agents, and investigated the role of over-molding a solid skin over a foamed core on the flexural strength of the molded component. Our approach is broken down into four distinct investigations—Study I investigated the effect of different graphene content by weight percentage (wt.%), namely 0.1%, 0.5%, and 1%, on flexural properties and foam morphology obtained for 15 wt.% reduction of the PP thermoplastic, thereby helping identify an optimum graphene loading wt.%. Study II broadened the wt.% reduction horizon for PP to 5 wt.%, 10 wt.%, and 15 wt.%, systematically analyzing the impact of the optimal graphene loading and comparing their cell morphology and flexural properties. This improvement in microstructure and mechanical properties was confirmed in the case of graphene addition to 10 wt.% and 15 wt.% reduction, where cell size was reduced by ~100% for 10 wt.% reduction samples and cell density improved from 4.37 × 105 cell/cm3 to 5.42 × 106 cell/cm3 for the same when compared to baseline PP foams. Study III serves as a demonstrator for a novel hybrid over-molding process designed to improve flexural properties. Over-molding with solid PP was performed over a foamed PP core, generating a composite foam with improved flexural strength and a class-A surface finish and noticeably improved flexural strength from 23.4 MPa to 27.3 MPa, achieving an overall 10 wt.% reduction. This is significant since it translated to a 16% improvement in flexural strength over baseline PP foams and a flexural modulus equivalent to solid PP. Study IV investigated the impact of this light-weighting to assess the potential energy savings over a typical passenger vehicle’s life cycle. The study demonstrates a viable route to achieve sustainable vehicle light-weighting and highlights the role supercritical fluid-assisted foamed thermoplastic nanocomposites may occupy in the vanguard of sustainable material development.
Pradeep, Sai Aditya, Deshpande, Amit Makarand, Shah, Bhavik, Khan, Saida, Farahani, Saeed, Sternberg, James, Li, Gang, Pilla, Srikanth
Design and Optimization of Lightweight Alloys for Automotive ApplicationsSAE-PP-004007/22/2024
Effective integration of lightweight materials is becoming more and more important to the automobile industry as a means of improving vehicle efficiency, performance, and sustainability. A key element in accomplishing these goals is the use of lightweight alloys, which are distinguished by their high strength-to-weight ratios and customized mechanical properties. Using databases and computer tools like CES EduPack, this study investigates the design and optimization of lightweight alloys for automotive body panels, guaranteeing that the materials chosen are both economically and environmentally sustainable. The results of the study offer insightful data on developing more efficient automobile alloys in the future, advancing the field of sustainable automobile technology.
Al-Ezzi, Athil
Investigation on Mechanical Properties of Hemp Fiber-Reinforced in Cellulose Acetate Composite Compared with Other Fiber Composites2024-01-50737/19/2024
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.
Assessing the Structural Feasibility and Recyclability of Flax/PLA Bio-Composites for Enhanced Sustainability2024-26-04076/1/2024
Bio-composites have gained significant attention within the aerospace industry due to their potential as a sustainable solution that addresses the demand for lightweight materials with reduced environmental impact. These materials blend natural fibers sourced from renewable origins, such as plant-based fibers, with polymer matrices to fabricate composite materials that exhibit desirable mechanical properties and environmental friendliness. The aerospace sector's growing interest in bio-composites originates from those composites’ capacity to mitigate the industry's carbon footprint and decrease dependence on finite resources. This study aims to investigate the suitability of utilizing plant-derived flax fabric/PLA (polylactic acid) matrix-based bio-composites in aerospace applications, as well as the recyclability potential of these composites in the circular manufacturing economy. The bio-composite laminate is produced through a compression molding process involving interleaved layers of PLA and flax fiber mats. We discuss the manufacturing technique, mechanical behavior, thermal characteristics properties of the bio-composite. A thorough comparison is drawn between these properties and those of similar bio-composites. Moreover, the study emphasizes the recycling of these bio-composites using mechanical milling, and their subsequent use as additives in the original fiber mat laminated composites. A comprehensive evaluation is conducted, contrasting the attributes of the original laminate with those of the laminate containing recycled additives. The outcomes of this study will contribute to understanding and assessing the sustainability of bio-based polymer applications. By examining the performance of flax/PLA bio-composites in aerospace composite material qualification settings and investigating their recyclability, this research reveals the viability as an eco-friendly alternative in the aerospace industry, aligning with the industry's ongoing efforts to adopt greener practices and materials.
B S, Dakshayini, Kancherla, Kishore Babu, Raju, Benjamin, Roy Mahapatra, Debiprosad
What's the Best DC Motor for Your Commercial Aerospace Application?24AERP05_025/1/2024
In commercial aerospace, the application areas for motors are wide and varied, each with their own unique requirements. From electric vehicle take-off and landing (eVTOL) air taxis to business jets to long-haul commercial transport aircraft, DC motors must endure various environmental conditions like extreme temperatures, shock and vibration, atmospheric pressures and signal interference, to name just a few. These applications may also demand motors that provide a fast response, high power or torque density. In addition to these requirements, the aerospace industry perpetually calls for lightweight materials and smaller installation spaces. Taken together, it can be very difficult to specify and buy a reliable motor for mission-critical equipment. This article will present common commercial aerospace applications that pose performance and environmental challenges for DC motors along with a summary of the stringent aerospace industry standards that the motors must satisfy. It will also provide an overview of BLDC and DC motor types, the attributes to look for when specifying motion control components for various commercial aerospace applications, and customization options to ensure optimal reliability and a long lifetime.
Enhancement of Physical and Mechanical Attributes of a Natural Fiber-Reinforced Composite for Engineering Applications2024-01-22374/9/2024
A natural fiber based polymer composite has the advantage of being more environment-friendly from a life cycle standpoint when compared to composites reinforced with widely-used synthetic fibers. The former category of composites also poses reduced health risks during handling, formulation and usage. In the current study, jute polymer laminates are studied, with the polymeric resin being a general purpose polyester applied layer-by-layer on bi-directionally woven jute plies. Fabrication of flat laminates following the hand layup method combined with compression molding yields a jute polymer composite of higher initial stiffness and tensile strength, compared to commonly used plastics, coupled with consistency for engineering design applications. However, the weight-saving potential of a lightweight material such as the current jute-polyester composite can be further enhanced through improvement of its behavior under mechanical loading. A weakness of a natural fiber reinforced composite is its propensity for moisture absorption which can lead to a substantial degradation in its stiffness and strength. In the current study, it is shown that addition of a limited number of plies of a lightweight metal such as an aluminum alloy in a meshed state can lead to substantive improvement in its physical and mechanical properties such as a 7.4% drop in mass for same surface area, a 57% increase in tensile modulus and a 12% rise in tensile strength. A noticeable enhancement in hygroscopic response of the hybrid jute composite has also been found in the moisture-absorption study that was carried out. It is noted that the hybrid jute-aluminum laminate investigated here has not been reported earlier in published literature. The current strategy of hybridization can be potentially extended to a wider class of natural fiber reinforced polymeric composites.
Karthika, M R, Deb, Anindya, Arockiasamy, Madasamy
AZ31-MWCNT Composites Fabricated Through Powder Metallurgy for Aerospace Applications2024-01-19383/5/2024
The aerospace industry's unceasing quest for lightweight materials with exceptional mechanical properties has led to groundbreaking advancements in material technology. Historically, aluminum alloys and their composites have held the throne in aerospace applications owing to their remarkable strength-to-weight ratio. However, recent developments have catapulted magnesium and its alloys into the spotlight. Magnesium possesses two-thirds of aluminum's density, making it a tantalizing option for applications with regard to weight-sensitive aerospace components. To further enhance magnesium's mechanical properties, researchers have delved into the realm of metal matrix composites (MMCs), using reinforcements such as Alumina, Silicon carbide, Boron carbide and Titanium carbide. However, meager information is available as regards to use of Multi-Walled Carbon Nanotubes (MWCNTs) as a reinforcement in magnesium based MMCs although, CNTs exhibit excellent stiffness coupled with very low density. In the light of above, the present work focusses on development of lightweight magnesium based MMCs using CNTs as nano-fillers. This research explores the synthesis and characterization of MWCNT-reinforced AZ31 magnesium alloy composites. The weight fractions of MWCNTs were varied from 0.3% to 1.2% in steps of 0.3%. Powder metallurgy technique has been used to develop the composite. Ball milling was used to blend the composite mixture of AZ31 & CNTs. Microstructural studies such as optical micrograph, scanning electron microscopy (SEM) and transmission electron microscopy (TEM) have been carried out on the developed composites. Micro hardness and compression strength tests have been carried out on the developed composite. X-ray diffraction (XRD) and Energy Dispersive Spectroscopy (EDS) studies have also been carried out to analyze the compositional elements present in the developed composite. Microstructural studies reveal a fairly uniform distribution of CNTs within the matrix alloy AZ31. A significant improvement in both hardness and compressive strength have been observed for the developed composites when compared with the base alloy.
Mukunda, Sandeep, Boppana, Satish Babu, Chinnakurli Suryanarayana, Ramesh, T, Aravinda, Khan, Saleem
Microstructure, Worn Surface, Wear Assessment and Taguchi’s Approach of Titanium Alloy Hybrid Metal Matrix Composites for Automotive Applications2023-01-51032/23/2024
Lightweight materials are in great demand in the automotive sector to enhance system performance. The automotive sector uses composite materials to strengthen the physical and mechanical qualities of light weight materials and to improve their functionality. Automotive elements such as the body shell, braking system, steering, engine, battery, seat, dashboard, bumper, wheel, door panelling, and gearbox are made of lightweight materials. Lightweight automotive metals are gradually replacing low-carbon steel and cast iron in automobile manufacture. Aluminium alloys, Magnesium alloys, Titanium alloys, advanced high-strength steel, Ultra-high strength steel, carbon fiber-reinforced polymers, and polymer composites are examples of materials used for light weighing or automobile decreased weight. The ever-present demand for fuel-efficient and ecologically friendly transport vehicles has heightened awareness of lowering weight and performance development. Titanium alloys properties are increasing in the variety of applications in automotive parts such as fuel tanks, exhaust pipes, engine parts such as connecting rods, engine valves, reinforcing and stiffening parts, sub frames, body panels, fuel cell components, and electrification components. Motorcycles and automobiles that demand high dynamic performance, such as racing cars and bikes, commercial vehicles, and cargo trucks, must increase time on the circuit and have a good reaction. As a result, titanium alloys are frequently used to significantly reduce weight while increasing the performance output of automotive systems. The innovative investigation of titanium metal matrix (Ti-6Al-4V) composite with added multi reinforcement of tungsten carbide particles (WCp) and graphite particles (Grp) were examined on its tribological behavior. The Ti-6Al-4V built-in different composites Ti-6Al-4V/4%WCp/4%Gr and Ti-6Al- 4V/8%WCp/8%Gr with a size of WCp and Gr was 44μm and 15μm invented through stir casting. The investigations were carried out as wear experiments using a pin-on-disc tribometer in dry sliding circumstances at three distinct load (15N, 20N, 25N), sliding distance (1000m, 2000m, 3000m), and sliding velocity (2.5m/s, 4.5m/s, 6.5m/s). The significance of various strictures on wear analysis was investigated using Taguchi’s L27 orthogonal array approach. The findings of Taguchi’s and design of experiment show that the variables most likely to have an impact on wear loss is load, sliding distance, and sliding velocity. The composites bonding structure and wear surface were examined using an optical microscope and a field emission scanning electron microscope. The wear tests reveal that the treated Titanium alloy hybrid metal matrix composites with tungsten carbide and graphite particles have excellent wear qualities with a sliding velocity of 6.5 m/s and a load of up to 35 N in the region with the lowest wear loss of 0.039mm3/m. This study adds additional data to the dry slide wear resistance of composite consisting of Ti-6Al-4V alloy and reinforced through WCp with Grp, which are ideal for usage in automotive and transportation applications. The automotive industries employed dynamic conditions resulting in wear loss. To reduce wear and increase vehicle economy and performance, the tribological behavior was researched.
Ramana Murty Naidu, S. C. V., Kalidas, N., Venkatachalam, Sivaraman, Mukuloth, Srinivasnaik, Asary, Abdul Rab, Naveenprabhu, V., Vishnu, R., Vellingiri, Suresh
NVH-fighting plastic EV motor mount wins lightweighting award24AUTP02_092/1/2024
Most motor mounts, even for EV applications, are made of metal alloys. It makes intuitive sense: It's a vibration-intensive mounting application that demands durability that matches the life of the vehicle itself. But there is another way. Now, a composite nylon-based motor mount on the Cadillac Lyriq has won the Society for Automotive Analysts' Innovation in Lightweighting Award. The mount is a collaboration between GM, anti-vibration parts maker DN Automotive and chemical company Celanese. It is made with Zytel PA NVH Gen 2, a new polyamide (PA 66). The results not only showed up in development data, but in the end product, which has reviewers raving about how quiet the Lyriq's cabin is - “crypt quiet,” according to Automotive News.
Clonts, Chris
A Lightweight Material Stronger than SteelTBMG-500022/1/2024
Working on the nanoscale gives researchers a lot of insight and control when fabricating and characterizing materials. In larger scale manufacturing, as well as in nature, many materials have the capacity for flaws and impurities that can disrupt their complex structure. This creates several weak points that can easily break under stress. This is common with most glass, which is why it is thought of as such a delicate material.
Geometry, Sizing and Optimization of Honeycomb Structures along with Embedded Metal Inserts on the Floor for Truck-Mounted Container Applications2024-26-01861/16/2024
With the rise of worldwide trends towards light weighting and the move towards electric vehicles, it is now more important than ever for the automotive industry to develop and implement lightweight materials that will result in significant weight reduction and product improvements. A great deal of research has been done on how to best combine and configure honeycomb cores with the right face sheets for Truck-Mounted Container Applications. Honeycomb structures possess the ability to bring about superior structural rigidity when the core parameters are selected and optimized based on the automotive application requirements. Through a variety of experimental tests for various combinations of the core parameters, the selection of the critical honeycomb core parameters to efficiently increase the compressive strength and panel rigidity of the entire container assembly has been evaluated and compared in order to determine the most effective combination to produce superior results for automotive applications specific to container segment. The current study also describes the challenges that were faced when using honeycomb core structures for chassis installation as well as the extensive research that was done to identify the optimal option. As all loads and fastening will induce higher forces on the floor mountings, it became crucial to design appropriate metal inserts at these truck mounting locations in order to support these loads/forces and ensure proper distribution to the complete floor panel. Keeping this objective, various metal insert designs with different geometric characteristics were studied and experimental trials carried out in order to arrive at the optimum design sizing for best performance. The specifications of the metal insert built-in the floor panel to achieve the desired result of withstanding the container loads are also highlighted in the study.
Phukan, Prerna, Dave, Rajeev
Taguchi’s Approach to Wire Electrical Discharge Machining of Magnesium Alloy AZ31B2023-28-013611/10/2023
One of the most common types of lightweight materials used in aerospace is magnesium alloy. It has a high strength-to-weight ratio and is ideal for various applications. Due to its corrosion resistance, it is commonly used to manufacture of fuselages. Unfortunately, the conventional methods of metal cutting fail to improve the performance of magnesium alloy. One amongst the most common methods used for making intricate shapes in harder materials is through Wire-Electro-Discharge (WEDM). In this study, we have used magnesium alloy as the work material. The independent factors were selected as pulse duration and peak current. The output parameters of the process are the Surface Roughness (SR) and the Material Removal Rate (MRR). Through a single aspect optimization technique, Taguchi was able to identify the optimal combination that would improve the effectiveness of the WEDM process. The findings of the experimentation revealed that the technique could significantly enhance the wire-cut process’s efficiency.
Natarajan, Manikandan, Pasupuleti, Thejasree, Kumar, V, Krishnamachary, PC, Kiruthika, Jothi, Kotapati, Gowthami
Development of Hybrid Natural Fiber Reinforced Composite Material for Automotive Applications2023-28-013111/10/2023
Industrialization concerns are stimulating research in development of new materials for automotive industries. Natural fibers which are available abundantly can be extracted naturally from environment. Preventing further pollutants on environment from depleting dwindling wood resources from forests and earth surface. Natural fibers are derived from renewable sources, making them environmentally friendly. Their use in composites reduces dependence on non-renewable resources and helps lower the carbon footprint of automobiles. Natural fibers, such as hemp, jute, and flax are lightweight materials. By incorporating them into polymer composites, the overall weight of automobile components can be reduced, leading to improved fuel efficiency and lower emissions. Natural fibers are generally less expensive than synthetic fibers, incorporating natural fibers into polymer composites can help reduce material costs in automobile manufacturing. Natural fiber polymer composites can be recycled at the end of their life cycle, contributing to a more sustainable automotive industry. In this project work, we have opted Hemp and Short carbon as fiber composite and prepared three composites of Hemp, Short Carbon and hybrid composite of both fibers. The composites are prepared by employing Hand Lay-up technique and evaluated the Density, Water Absorption Tensile Strength, Flexural Strength of the Hemp, Short Carbon and Hemp/Short Carbon fiber reinforced polymer matrix composites.
Malkapuram, Devaiah
Multiple Regression Analysis for Ti-6Al-4V Wire Electrical Discharge Machining (Grade 5) for Light Weight Automobile Applications2023-28-016311/10/2023
Wire Electrical Discharge Machining (WEDM) is a variant of the electrical discharge machining (EDM) process, which represents an innovative method for the removal of material from a workpiece. The aforementioned process is frequently employed for the machining of harder materials that possess intricate geometries. Titanium alloys are a class of lightweight materials that find extensive utilization in many technical applications. Titanium Grade-5 is a titanium-based alloy that exhibits enhanced mechanical strength and improved resistance to corrosion. The objective of this exploratory analysis is to establish empirical correlations between the selected input variables, namely ‘Pulse on,’ ‘Pulse off,’ and peak current, and the desired output measures, which are material removal rate and surface roughness. The experimental design employed the Taguchi method to effectively organize the combination of tests by considering input factors. Multiple regression analysis has been developed to establish the relationship between selected input and output variables. Contour and interaction analysis were done to divulge the interaction effect of independent factors on individual output metrics. The results of the multiple regression analyses were then analyzed to ascertain the link amongst the various input factors and the outputs.
Natarajan, Manikandan, Pasupuleti, Thejasree, D, Palanisamy, Umapathi, D, Kiruthika, Jothi, Kotapati, Gowthami
Machinability Investigations on Ti-6Al-4V (Grade 5) Wire Electrical Discharge Machining Using Taguchi Method for Auto Parts2023-28-014411/10/2023
Titanium alloys are deemed as one amongst the light weight material most preferably adopted in numerous engineering applications due to its exceptional features such as corrosive resistance and thermal strength. These alloys are predominantly used in components of IC engines such as valves and springs, connecting rods. Especially Ti-Grade 5 adopted in aircraft, automobile parts ski plates and bicycles. The preliminary goal of this present research is to optimize the machining variables for Wire Electrical Discharge Machining (WEDM) of Ti-6Al-4V (Grade 5) to accomplish improved rate of material removal and surface finish. Taguchi’s design and analysis method was chosen for devising and examining the experiments by considering input factors (pulse duration and current). An L9 OA was utilized for experimentation to analyze the various output variables, such as surface finish and material removal rate, using the response analysis of Taguchi. ANOVA and interaction analysis also performed to reveal the significance of factors and their interaction effects. The findings of this explorative analysis will helpful for the manufactures to improve the machining performance.
Pasupuleti, Thejasree, Natarajan, Manikandan, Katta, Lakshmi Narasimhamu, Somsole, Lakshmi Narayana, Kiruthika, Jothi, Silambarasan, R
Lightweight, Self-Deployable Helical AntennaTBMG-489219/1/2023
Historically, patch antennas have been used for SmallSat communications. While new antenna technologies are in development, some are not optimized for size, mass, and performance — especially beyond low-Earth orbit (LEO). Engineers at NASA’s Marshall Space Flight Center identified the need for a small form factor antenna to provide high data rate communications for such missions.
Numerical Analysis of Lightweight Materials and their Combinations to Understand their Behaviour against High Pressure Shock Loading2023-28-13115/25/2023
Materials play a key role in our day to day life and have shaped the industrial revolution to a great extent. Right selection of material for meeting a particular objective is the key to success in today’s world where the cost as well as sustainability of any equipment or a system have assumed greater significance than ever before. In automotive industry, materials have a definitive role as far as the mobility and safety is concerned. Materials that can absorb the required energy or impact can be manufactured through different manufacturing as well as metallurgical processes which involves appropriate heat treatment and bringing correct chemical compositions etc. However, they can also be formed by simpler methods such as combining certain materials together in the form of layered combinations to form light weight composites. Analyzing the response of different materials during incidents such as high-speed impact or transmission of shock waves as a result of earthquakes, tsunami or manmade disasters like explosion, is of great importance. Those materials which can respond in a desirable manner to meet a particular requirement during the most undesirable conditions such as high energy impacts can be termed as high energy absorbing materials and they play a crucial role in designing important structures, frames, protective vehicles and equipments, sacrificial components and claddings etc. These materials and structures need to be tested for their strength and design against adverse loading conditions. In this paper, different materials like steel, aluminum and aluminum-rubber combination are analyzed to understand their response during high pressure loading incidences. Judicious and scientific application of these materials can ensure a much better protection to different structures of importance, buildings as well as in defence, aerospace and automotive related applications. There are different methods of analyzing the strength and capabilities of materials or their combinations such as experimental, lab and simulation method. Out of these, the simulation (numerical analysis) method is one of the most appropriate methods which give very accurate results as compared to other methods. Here, Ansys- Autodyn simulation is used to draw the analysis of the materials and their combinations under high pressure shock loadings, resulting due to explosion or blast, and the total energy, pressure, displacement and velocity parameters are studied and compared.
Singh, Swati, Chauhan PhD, R. S., Sandhu PhD, Inderpal Singh, Sharma PhD, Prince
“IMC Technology for Light Weighting”2023-28-13085/25/2023
Over the last decade, Climate change due to fossil fuel burning has taken centre stage in all discussions. Automotive sector has come under some flak for being one of the contributors to this Climate Change. Active steps have been taken by Vehicle Manufacturers and their Suppliers to address this issue. This sector has been facing below challenges to reduce pollutant in the air by A. Reducing Emissions, B. Increasing Energy Efficiency C. Use of Renewable Energy. One of the many alternatives by the Automotive Industry was to have a phased introduction to Electric Vehicles (EV), Hybrids, Fuel cells and other variants. As various emission norms and safety requirements takes Centre stage, it invariably, increases the weight of the vehicle. Now a days, Vehicles are having challenges to make it lightweight to achieve Range for an EV and improve fuel efficiency without sacrificing safety. It has also been observed that the weight of a vehicles is more due to the Structural Members made out of metal to meet all the Safety Norms. Innovative plastics and fiber reinforced composite materials offer a means to lightweight vehicle structures. Injection Moulding Composites (IMC) is one of the Technology to achieve this Light weighting target. IMC Technology is the combination of the Injection Moulded Process and Reinforcement Material to achieve the desired result. IMC is a suitable Technology for conversion of Metal to Plastics for Structural Parts, which gives the required strength and reduces weight of the parts. The IMC has a significant advantage over a traditional injection molding machine. With the IMC, the processor can compound his own material himself, i. e. introduce fibers, fillers or master batches, into the process directly during processing. Since the material purchasing represents the largest cost block in the injection molding of a part, the use of an IMC increases cost efficiency. Compared with premixed compounds, the purchasing of individual components is much more cost effective.
GEORGE, ANIL, KHACHANE, BHUSHAN HEMRAJ
Development and Performance Studies of a Lightweight AA6061/Ti Particulate Surface Composite through Friction Stir Processing2023-28-13035/25/2023
Surface engineering is becoming increasingly crucial for several automotive and aerospace components that involve intense surface interactions. Friction stir processing (FSP) has emerged as an effective surface modification and hardening technique in recent days. The technique also allows the incorporation of reinforcement into the modified surface to enhance the strength and hardness further. This work applied FSP to develop a pure Ti particulate reinforced AA6061 metal matrix composite (MMC). Six different strategies were adapted (in the form of micro grooves, micro drills on the surface) to effectively infuse reinforcement on the alloy surface. Microstructural changes before and after FSP were studied using SEM and EBSD. Other tests such as post-mortem EDS, XRD, hardness, and compression were also done to examine the performance of developed composite. Microstructural lineaments revealed a more uniform dispersion of reinforcement particles in the matrix when the particles were impregnated using a multi-groove approach. Details on the development strategy, microstructural evolution and various strengthening mechanisms involved in enhancing the mechanical properties are presented in this manuscript.
Hussain, Ilyas, Immanuel, Jose
Sound Transmission Loss of Acoustic Metamaterial with Lightweight Frame and Hard Membrane-Like Material2023-01-10575/8/2023
To reduce the noise in the frequency range of 100Hz~1000Hz, a metamaterial structure composed of lightweight frame, hard membrane-like material and added mass is proposed in this paper. The advantage of this structure is that it is lightweight and the membrane-like material does not need to be stressed in advance. Finite element method (FEM) and experiment are used to investigate the sound transmission loss (STL) performance of the metamaterial structure. The results show that the peak STL is caused by the local resonance of the added mass and the membrane-like material. The valley versus frequency results from the resonance frequencies of metamaterial structure, and it is divided into three resonance frequencies: resonance frequencies from added mass, membrane-like material and frame. Frame resonance will influence vibration of membrane-like material, if the frequency of frame resonance is close to the frequency at peak STL, the frequency at peak STL will be changed and the amplitude of STL at the peak will be lowered. The effects of the elastic modulus, density and width of the frame on the STL are discussed. The result shows that the STL is sensitive to frame width, and it is concluded that the effect of frame resonance on STL can be decreased by reducing the frame width, and STL is greater than 20 dB in the range of 400Hz-900Hz.
Yang, Xu-Hao, Kang, Yingzi, Xie, Xinxing, Zhang, Qu, Shangguan, Wen-Bin
Rationale and Process for Developing an SAE Damping Test Method2023-01-10505/8/2023
The paper discusses the process of developing an SAE damping measurement test method that is suitable for testing bars that are not made of steel or are difficult to measure with the traditional Oberst bar method. The method is based on measuring mechanical impedance (force over velocity) of a vibrating bar. The bar is excited at the center using a shaker and hence it is also called a CenterPoint method. The paper discusses the round robin tests that have been conducted so far and discusses the test results that will help develop the standard. The paper discusses the variability of the round robin test results within a laboratory, between laboratories, as well as the coefficient of variation for these measurements. The paper also discusses various parameters that should be carefully monitored in this study, that otherwise could affect the precision of the test procedure.
Saha, Pranab, Anderson, Codi
Full Aluminum Body Design Considering Part-Specific Requirements2023-01-06034/11/2023
In the era of electric vehicles(EVs), the need for weight reduction of the vehicle body is increasing in order to maximize the driving distance of the EV. Accordingly, there is an increasing need for research to efficiently apply lightweight materials, such as aluminum and CFRP, to the EV body parts. In this study, design methodologies and optimization measures to increase lightweight efficiency when applying lightweight materials to EVs will be discussed. Based on theoretical basis and basic performance of each part of the EV, the “Material Substitution Method” of replacing existing parts of a steel body with aluminum materials will be defined, and the optimal design process on how to overcome performance trade-off caused by material characteristics will be addressed. In applying the “Material Substitution Method” to the actual EV body design process, it was possible to convert 93% of the components from steel to aluminum and reduce the overall weight of the body by 23%. Based on these results, the “Material Substitution Method” helps secure basic performance for each part with relative ease when changing the material of the body part from steel material to lightweight material (AL, CFRP, etc.). In addition, it is verified that the optimal design process defined in this paper is effective in maximizing the weight reduction efficiency of the lightweight body.
An, Byeongdo, Cha, Munsoo, An, Yongdok, Kim, Heeju, Oh, Heedae, Kim, Kyungbo, Jang, Younghoon, Nam, Byeunggun, Chun, Yunbae, Lee, Hunky
Light Weight Material for Entry Assist Grab Handle with Gas Assist Technology2023-01-08754/11/2023
Ground clearance plays a vital role in an off-road vehicle during off roading. Higher the ground clearance, higher is the difficulty during ingress & egress of the vehicle. This brings in the necessity to provide entry-assist grab-handles for vehicle with more ground clearance (>200mm). Entry-assist grab handles alleviates the pain of the occupants during ingress and egress. For entry-assist grab handles’ purpose to be served, it should provide comfortable ergonomic grip & have to take the load of passengers while ingress or egress through-out the complete life cycle of the vehicle. Entry Assist grab handles can be fitted on A-Pillar zone to assist first row passengers & on B-pillar zone to assist second row passenger. Providing entry-assist grab handles on pillar trims make the grab-handles exposed to head-impact zone and hence, in most of the cases, it should pass the head impact regulations framed for respective countries. This paper dwells upon the importance of a material used for entry-assist grab handle purpose in meeting durability, and safety targets as per regulation. The proposed material grade also shows reduction in weight as compared to the conventional materials used for Entry Assist Grab handle. Not-withstanding, we have discussed the behavioral comparison of different materials that are used conventionally and the key benefits for the proposed material are discussed in the paper. The proposed material is also compatible to be manufactured by Gas assist injection molding process.
Khairnar, Prashant Dattatray, D, Gowtham, D, Anantha, Bornare, Harshad, Kakani, Phani Kumar, Sriperumbudur, Srivatsa
Crack Detection and Section Quality Optimization of Self-Piercing Riveting2023-01-09384/11/2023
The use of lightweight materials is one of the important means to reduce the quality of the vehicle, which involves the connection of dissimilar materials, such as the combination of lightweight materials and traditional steel materials. The riveting quality of self-piercing riveting (SPR) technology will directly affect the safety and durability of automobiles. Therefore, in the initial joint development process, the quality of self-piercing riveting should be inspected and classified to meet safety standards. Based on this, this paper divides the self-piercing riveting quality into riveting appearance quality and riveting section quality. Aiming at the appearance quality of riveting, the generation of cracks on the lower surface of riveting will seriously affect the riveting strength. The existing method of identifying cracks on the lower surface of riveting based on artificial vision has strong subjectivity, low efficiency and cannot be applied on a large scale. Therefore, based on image processing and computer vision, this paper proposes an automatic identification method of surface cracks under self-piercing riveting based on convolutional neural network (CNN) and local-global strategy. Aiming at the quality of riveting section, the riveting process and section quality are analyzed by numerical simulation, and a multi-objective optimization method is proposed to assist in improving the quality of riveting section.
Wang, Kun, Zhan, Zhenfei, Xu, Hailan, Hu, Ke, Chen, Xiatong
Friction and Wear Studies on Jute Fiber and SS 304 Wire Mesh Reinforced Hybrid Polymer Composites for Automotive Applications2023-01-07274/11/2023
Automotive industry is looking for high strength and durable lightweight material with resistance to wear and friction. To meet this requirement, a new hybrid polymer composite material has been developed using reinforcement as SS 304 wire mesh and jute fibre. Present paper explores the experimental findings of wear performance of hybrid polymer composite under dry condition. Four different laminates with configurations JJSJJSJJ, (JJSJJSJJ)450, GGSGGSGG and GJSJJSJG along with their virgin counterpart were developed by hand layup technique supported by compression moulding. These laminates were tested as per the ASTM standards to investigate its performance for friction and wear using pin on disc machine with steel as a counterpart. Testing parameters were sliding distance, applied load and sliding speed. Experimental results showed that, applied load have major influence on the friction and wear performance of developed hybrid composites. As load rises, friction force value increases with increased specific wear rate for entire composites. With hybridization of composite laminates, the frication and wear performance has improved as their virgin counterpart. The study demonstrates that wire mesh added to hybrid polymer composites during manufacturing increases the composite's wear resistance. This developed hybrid composite material has great potential to replace metal or alloy in automobile door trim panels where friction and wear are dominates.
Salve, Aniket Vinayak, Mache, Ashok
A Method for Measuring In-Plane Forming Limit Curves Using 2D Digital Image Correlation05-16-03-00194/10/2023
With the introduction of advanced lightweight materials with complex microstructures and behaviors, more focus is put on the accurate determination of their forming limits, and that can only be possible through experiments as the conventional theoretical models for the forming limit curve (FLC) prediction fail to perform. Despite that, CAE engineers, designers, and toolmakers still rely heavily on theoretical models due to the steep costs associated with formability testing, including mechanical setup, a large number of tests, and the cost of a stereo digital image correlation (DIC) system. The international standard ISO 12004-2:2021 recommends using a stereo DIC system for formability testing since two-dimensional (2D) DIC systems are considered incapable of producing reliable strains due to errors associated with out-of-plane motion and deformation. This work challenges that notion and proposes a simple strain compensation method for the determination of FLCs using a low-cost single-camera (2D) DIC system. In this study, formability tests are performed on an automotive-grade 6xxx series aluminum alloy using the Marciniak in-plane FLC testing method. The tests are performed on a custom setup that enables simultaneous optical strain measurements using a stereo DIC as well as a 2D DIC system. The results show how 2D DIC FLC points match those obtained by stereo DIC using two popular FLC approaches: ISO 12004-2 section-based spatial method and a time-dependent linear best fit (LBF) method.
Agha, Akshat, Abu-Farha, Fadi
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