Browse Topic: Metals

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Effect of Shot Peening on the Fatigue Life of Polylactic Acid Parts in Automobiles2026-28-0032To be published on 02/01/2026
Polylactic Acid (PLA), is a biodegradable thermoplastic and most widely used materials in automobiles also inherent fatigue performance limitations and its deployment in demanding load-bearing automobile applications. Shot peening, a well-established surface treatment known to significantly enhance the fatigue life of metallic materials, presents a potential post-processing strategy to improve the durability of polymers. The proposed work investigation into the effects of controlled shot peening pressure on the various behavior of injection molded PLA specimens. The outlined methodology encompasses the fabrication of PLA samples conforming to ASTM standards, the application of shot peening using precisely defined parameters, comprehensive characterization of the resulting surface modifications (including roughness, hardness, morphology, and systematic uniaxial fatigue testing according to ASTM D7791. Fatigue tests will generate fatigue behavior and fatigue life (by varying number of
Ranganathan, Soundararajan
AI-Driven Process Optimization in Wire Arc Additive Manufacturing of Nickel Alloys Using ANFIS2026-28-0025To be published on 02/01/2026
Wire Arc Additive Manufacturing (WAAM) is gaining significance in recent years as a process for additive manufacturing that produces large and complex components with high deposition rates at economically feasible rates. Nickel-based alloys, praised for their unique features, like mechanical strength, corrosion resistance, and thermal stability, find widespread application in the aerospace, marine, and energy sectors. However, achieving the desired surface finish, dimensional precision, and mechanical performance of WAAM nickel alloy structures is a continuing challenge because of the complex interactions occurring between the process parameters. The study presents an experimental analysis conducted to establish the effect of important process parameters of WAAM-wire feed rate, travel speed, welding current, interpass temperature-on the quality indicators such as surface roughness, dimensional accuracy, and hardness. For the purpose of prediction and process control, the Adaptive Neuro
Natarajan, Manikandan
TOPSIS-Based Multi-Criteria Optimization of WAAM Parameters for Automotive Component Fabrication2026-28-0026To be published on 02/01/2026
Wire Arc Additive Manufacturing (WAAM) can make huge, complicated metal parts quickly and cheaply, making it popular in the automobile sector. This study uses TOPSIS, a multi-criteria decision-making method, to improve WAAM process parameters such wire feed rate, travel speed, and current. Automotive applications need surface roughness, deposition rate, and dimensional precision, which WAAM-fabricated components must meet. TOPSIS normalizes and ranks experimental findings to find parameter combinations that perform best across many quality metrics. The results show that integrated optimization improves component quality and consistency, making WAAM a feasible and economical sustainable vehicle manufacturing option.
Pasupuleti, Thejasree
Modelling and Analysis of Complex Shaped Cracks2026-28-0048To be published on 02/01/2026
This study offers a thorough analysis using finite element methods (FEA) to examine how fatigue cracks grow in three different materials: Structural steel , Titanium alloy (Ti Grade 2), and epoxy/aramid-based printed circuit board (PCB) laminates. Using ANSYS Workbench, we ran simulations under both static and repeated loading to understand how these materials fracture. The approach was based on Linear Elastic Fracture Mechanics (LEFM), employing the Maximum Circumferential Stress Criterion to predict where cracks might start and how they could spread. Also, the Equivalent Domain Integral (EDI) method helped us calculate the Stress Intensity Factors (SIFs) when cracks are under mixed loading modes. We modeled the growth of fatigue cracks using the Paris Law, relying on material-specific constants (C and m) drawn from previous studies and experimental tests. For example, titanium Grade 2 showed Paris Law constants with C values between 1.8 × 10⁻¹⁰ and 7.9 × 10⁻¹² m/cycle, and m values
T, LOKESH, Bhaskara Rao, Lokavarapu
Experimental Investigation of Process Parameter Effects in WAAM of Nickel-Based Alloys2026-28-0027To be published on 02/01/2026
Wire Arc Additive Manufacturing (WAAM) is an evolving discipline in metal additive manufacturing characterized by rapid deposition, cost-effectiveness, and centrality to the near-net-shape fabrication of large-scale components. This study will concentrate on WAAM application to deposit nickel alloys, which find extensive use in aerospace, power generation, and marine industries, due to their good mechanical strength, corrosion resistance, and thermal stability. However, some drawbacks in WAAM processing of nickel alloys include thermal distortion, porosity, and residual stress. The research looks at how key WAAM process parameters, including wire feed rate, travel speed, current, and interpass temperature affect geometric accuracy, surface integrity, and mechanical performance of the fabricated components. Microstructural characterization was done using optical microscopy, and hardness distribution was measured as an indication of mechanical uniformity throughout the builds. It is
Natarajan, Manikandan
Synthesis, characterization and electro active properties of poly (Meta Toudine-co-Fluro aniline) Ag dispersed nanocomposites: Shielding Composite as surface Coat or Enclose the ECU Housing for preventing signal distortion and ensuring reliable engine performance2026-28-0022To be published on 02/01/2026
A series of electroactive nanocomposites of silver dispersed poly (metatoludine-co-o-fluroaniline) copolymer has been prepared by in-situ polymerization method. The chemical molecular structures are identified by using UV–visible spectra, FTIR, X-ray diffraction instruments, SEM analysis. We propose that these composite materials possess a Electromagnetic Shielding interference coat or enclose the engine control unit (ECU) housing in the form of surface coating or moulded shell in order to prevent signal distortion and ensuring reliable engine performance in automobiles. This composite material possesses lightweight, corrosion-resistant EMI shielding solution for ECU housings. Implementation of these products significantly reduced signal interference from nearby high-power electronics, ensuring stable engine operation. The proposed system offers a cost-effective, lightweight alternative to metallic shielding in vehicular electronics in automobile industries.
Pachanoor, Vijayanand, Kumar, V
Sustainable Machining of Aluminium Alloys: Experimental Insights into WEDM Process Optimization2026-28-0034To be published on 02/01/2026
The most advanced mathematics transforms aluminum alloys into one of the most highly intricate materials into practically any engineering application based on the mechanical properties of ductility and low fatigue sensitivity. The use of aluminum alloys permeates critical industries like aerospace and automotive, besides being strong contenders in other high-performance applications. Their inherent corrosion resistance certainly gives an edge to aluminum alloys for applications in rigorous service environments. Conventional manufacturing processes would not successfully create components with some geometrical complexity; hence, advanced machining processes are being developed. Among them is Wire Electrical Discharge Machining (WEDM), which is increasingly being adopted within the EDM family, as it efficiently machines hard and complex shapes at high accuracy. The present investigation deals with WEDM of aluminum alloy using Taguchi's design of experiments approach, while focusing on
Natarajan, Manikandan
Parameter Optimization for Improved Surface Finish in WAAM-Fabricated Steel Structures2026-28-0023To be published on 02/01/2026
Wire Arc Additive Manufacturing (WAAM) is a cost-effective and scalable metal additive manufacturing technique widely used for fabricating large metallic components. However, surface finish remains a critical challenge, especially for structural applications where post-processing needs to be minimized. This study focuses on optimizing key process parameters to improve the surface finish of ER70S-6 steel structures fabricated using the WAAM process. Experiments were designed using a statistical approach to systematically vary parameters such as wire feed rate, travel speed, voltage, and inter-pass cooling time. Surface roughness was measured using standard metrology tools, and the results were analyzed to identify the most influential parameters. An optimized parameter set was proposed based on the experimental outcomes, leading to a significant reduction in surface roughness without compromising the structural integrity of the deposited material. The findings contribute to enhancing
PN, Vani
Influence of Copper oxide and Graphite additives on the lubrication performance of the engine oil2026-28-0017To be published on 02/01/2026
The parts of engine move at high speeds under heavy pressure. This leads to high temperatures and wear. To reduce the rate of wear, lubricants are used. But the lubricants are pollutants and increasing their useful life will result in the reduction of pollution. Additives may help in increasing the useful life of a lubricant. In the present study, the effect of the addition of cupric oxide and graphite nanoparticles to the engine oil on its performance of lubrication using pin on disc tribometer. AA2014 – 5 wt.% TiC composite material sliding against steel surface with lubricant was used to quantify the performance of additives. The base lubricant used in this study was 5W30 grade engine oil. Two types of lubricants, engine oil with 2 wt.% copper oxide (CuO) and engine oil with 2 wt.% Graphite (Gr) were tested and compared with the performance of the base oil in similar conditions. Adding Gr particles to the oil reduced the wear rate of sample by nearly 40% while CuO particles reduced
Ch, Sri Chaitanya, Mutyala, Venkata Ramarao, PONNAGANTI, Gopinadh Chowdary, Rajamalla PhD, Narasimha Rao, Bachugudem, Arun Kumar, Abdul Azeez, Mohammed, Kumar, Mohan
Evolution of a Novel Hybrid Stab-Link for a Born Electric Sports Utility Vehicle2026-28-0001To be published on 02/01/2026
The present study details the design evolution and failure analysis of a novel hybrid stabilizer bar link (stab link) developed for the front suspension of a born electric sports utility vehicle (SUV) platform characterized by higher gross vehicle weight (GVW), increased wheel travel, and constrained packaging space. To address these challenges, a unique hybrid stab link was designed featuring dual plastic housings at both the metal ball joint ends, connected by a steel tube, and achieving a 30% weight reduction while offering enhanced articulation angles for extremely lower turning circle diameter (TCD) of the vehicle, compared to the conventional stab link. The unique hybrid stab failed under complex loading conditions during accelerated durability testing (ADT), prompting a comprehensive investigation. The failure analysis included road load data acquisition across various stab bar diameter configurations evolved during suspension tuning, different stabilizer link designs evolved
SELVENDIRAN, P, J, Ramkumar, NAYAK, Bhargav, M, Sudhan, Patnala, Avinash
Experimental and Predictive Study on WEDM of Aluminium Alloys Using Taguchi and ANFIS2026-28-0040To be published on 02/01/2026
The attributes of aluminium alloys are acknowledged in the varied usage of these alloys because they have excellent mechanical properties and good ductility while being less vulnerable to fatigue. These alloys are widely applied in engineering disciplines. The aerospace and automotive industries are important industries using these alloys, and many other progressive engineering applications continue to embrace the use of these alloys. Their resistance to corrosion makes them even better suited for usage in some harsh environments. Unfortunately, producing parts with very complicated geometries through conventional machining techniques is still a challenge. To try to solve this limitation, there have been several advanced machining processes. Among them is Wire Electrical Discharge Machining (WEDM) - a specific form of Electrical Discharge Machining (EDM) for an effective solution for complex and hard-to-machine components. In this study, efforts have been made to study the WEDM process
Natarajan, Manikandan
Evaluating the Suitability of ADC12 for Sand Casting: Filling, Solidification, and Mechanical Properties2026-26-0296To be published on 01/16/2026
This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines
Subramani, Rajesh, Singh, Gajendra, Doddamani, Mrityunjay
Evaluation of Shear Trim Edge in HSLA Steel for Automotive Application2026-26-0286To be published on 01/16/2026
Quality of the Shear Trimmed edge of HSLA 550 steels is significantly affected by process variations such as Shear Trimming Clearance, trim tolerance, burr height and clamping force. All these parameters largely influence the characteristics of the Shear Affected Zone, a region on sheet metal where it undergoes deformation during the trimming process. The Shear Affected Zone is predominantly vulnerable to failure due to work hardening and the effects of strain rate, induced by the tonnage during the trimming operation. To assess the edge ductility of these materials, Tensile, Fatigue Strength, Die Punch Clearance, Roughness and Hardness Tests are carried out. These tests are crucial for applications that demand high formability and resistance to edge failure. Virtual simulation of edge trimming operation using elastoplastic material models in LS-Dyna have been performed to gain insights into burr formation and damage evolution during shearing. These simulations act as a precursor to
Thota, Badri Vishal, Kashyap, Amit, Bhuvangiri, Jaydev
Optimization of the Rodip CED Process Suitability through Strategic Fixture System for Enhanced Hood Gap and Flushness Control in Automotive Manufacturing2026-26-0486To be published on 01/16/2026
The Ro-dip Cathodic Electrodeposition (CED) process is latest technology used by Automotive Manufacturers for higher quality corrosion protection in new generation Automobiles. This process involves multiple 360-degree rotation of automotive body in white (BIW) which exert higher hydrostatic forces on large surface panels like Hood. For maintaining consistent gaps & flushness control at vehicle level, it is important to safeguard the dimensional stability of light weight (crash performance sensitive) steel Hood panel while undergoing through this CED process. This study investigates the enhancement of hood panel alignment through strategic optimization of support rod placement and quantity within the Ro-dip CED system. By conducting experimental trials and computational simulations, the research identifies critical deformation points and evaluates the impact of varying support rod configurations on dimensional stability. The outcome results demonstrate that positioning support rods at
Tile, Vikrant, Unadkat, Siddharth, ASKARI, HASAN, Jadhav, Devidas
Improvement study of Style steel wheel durability in Multiple pothole impacts2026-26-0539To be published on 01/16/2026
This study focuses on improving the durability of steel wheel rims subjected to Multiple Pothole which is commonly found in Indian village roads - a critical scenario affecting vehicle safety and wheel lifespan. Initial steel wheel designs often face significant deformation or failure under repeated strikes and resulting in tyre air loss due to wheel bend, prompting the need for enhanced performance standards. In this research, a combination of finite element modelling, experimental impact testing, and material optimization strategies were employed to assess and improve the structural integrity of steel rims. Key parameters such as rim profile geometry & material composition were systematically varied to evaluate their influence on impact resistance. Results demonstrate that strategic design modifications and material enhancements can significantly increase the rim's ability to absorb energy and resist bending without substantial weight penalties. The findings offer practical
DEsigan, Lakshmipathy, P, Praveen, K, CHANDRAMOHAN, C, Santhosh
Predictive Analysis and Risk Management of Nickel-Plated Aluminum Automotive Parts Exposed to Harsh Environmental Conditions2026-26-0305To be published on 01/16/2026
Aluminium is widely used across various industries due to its lightweight properties, high strength-to-weight ratio, and cost-effectiveness. However, its susceptibility to corrosion, particularly in harsh environmental conditions, presents challenges to its long-term durability and performance. To mitigate these issues, nickel plating was applied as a protective measure, creating a barrier to minimize aluminums' direct exposure to corrosive environments and enhance its resistance to degradation. In this study, nickel-plated aluminum was subjected to controlled corrosion testing under simulated real-world conditions, including high humidity, saline atmospheres, and industrial pollutants. The primary objective was to evaluate the effectiveness and longevity of nickel plating as a corrosion prevention method. Periodic observations and measurements were conducted to monitor material changes, such as surface degradation and corrosion product formation. The findings highlight the critical
NARAIN, ADITYA, Venugopal, Sivakumar, Gopalan, Vijaysankar, Varatharajan, Senthilkumaran
Effect of the Flow Forming Process on the Mechanical properties and Microstructure of GDC & LPDC cast aluminum alloy wheels.2026-26-0298To be published on 01/16/2026
Aluminum alloy wheels have become the preferred choice over steel wheels due to their lightweight nature, enhanced aesthetics, and contribution to improved fuel efficiency. Traditionally, these wheels are manufactured using methods such as Gravity Die Casting (GDC) [1] or Low Pressure Die Casting (LPDC) [2]. As vehicle dynamics engineers continue to increase tire sizes to optimize handling performance, the corresponding increase in wheel rim size and weight poses a challenge for maintaining low unsprung mass, which is critical for ride quality. To address this, weight reduction has become a priority. Flow forming [3,4], an advanced wheel production technique, offers a solution for reducing rim weight. This process employs high-pressure rollers to shape a metal disc into a wheel, specifically deforming the rim section while leaving the spoke and hub regions unaffected. By decreasing rim thickness, flow forming not only reduces overall wheel weight but also enhances strength and
Singh, Ram Krishnan, Medaboyina, HarshaVardhan, G K, Balaji, Gopalan, Vijaysankar, SUNDARAM, RAGHUPATHI, Paua, Ketan
Virtual Paint Shop: Automotive E-coating Process2026-26-0365To be published on 01/16/2026
The automotive paint shop is one of the most energy-intensive processes in vehicle manufacturing. This drives automotive OEMs to continuously improve production efficiency and reduce operational costs through digital twin technologies. Additionally, the push for shorter time-to-market emphasizes the need for simulation-based manufacturing processes—such as virtual testing and CAE simulations—to enable faster, data-driven decision-making early in the product development cycle, ultimately reducing cost and development time. Among the various stages in the paint shop, two of the most critical are: 1. Electro-dip coating (E-coating), also known as Electro-Deposition coating, which applies a corrosion-resistant primer to the Body-in-White (BIW). 2. Oven curing, which ensures the primer is properly bonded and cured for long-term protection and finish quality. To optimize these processes, a Dip-Drain-E-Coating simulation was developed using Siemens Simcenter STAR-CCM+. This simulation
Gundavarapu, V S Kumar, p, Vivekaanandan, Garg, Manish, Navelkar, Tanay, BS, Balachandran
Experimental Study on the Role of Hole Expansion Ratio in Enhancing Crashworthiness of Advanced High Strength Steel2026-26-0295To be published on 01/16/2026
To meet light weighting and safety target, the automotive industry is increasingly using advanced high strength steel (AHSS) materials and advanced manufacturing techniques for complex body parts. To improve energy absorption of automotive body parts, various steel grades are developed by steel manufactures with variety of properties ( YS, UTS, EL %, HER). Also, the formability of AHSS grades (TS > 980 MPa) is challenging due to its limited edge ductility. This study focuses on role of hole expansion ratio in energy absorption of AHSS material. In the study, different AHSS material with variety of microstructure and properties are experimented, with the aim to identify the optimum properties, that can help to enhance crash worthiness of formed part. From experimentation, it is evident that hole expansion ratio plays important role in determining edge ductility, as well as energy absorption. This study may not only help to improve crash performance but also help for light-weighting of
Jain, Vikas, Bandru, Shreenu, Nadarge, Harshad, Misal, Swapnali, Deshmukh, Mansi, Paliwal, Lokesh
Steel-based Laminates for Lithium-ion Pouch Cell of Electric Vehicles2026-26-0186To be published on 01/16/2026
Aluminium foils have gained traction with EV battery manufacturers for their pouch cell format. Over the years it has evolved as a material of choice, but it is still plagued by issues of stress concentration, swelling due to lower strength and stiffness of base aluminium layer. Preliminary investigation revealed that laminates using steel foil material (thickness <0.1mm) could be a potential candidate for EV pouch cell casing. Thus, steel-based laminate was developed meeting key functional requirements (e.g. barrier performance, insulation resistance, peel strength, electrolyte resistance, formable without cracking at edges, and heat sealing compliant). This innovative patented steel-based laminate was further used to manufacture pouch cell prototypes (maximum capacity 2.5Ah) for key performance tests (e.g. cell cycling, nail penetration and thermal runaway). The study paves the way for a low cost, sustainable and flexible yet strong steel-based laminate packaging material solution
Singh, Pundan Kumar, Raj, Abhishek, Kumar, Ankit, Chatterjee, Sourabh, Verma, Rahul Kumar, Samantaray, Bikash, Gautam, Vikas, Pandey, Ashwani
Assessing the impact of hole piercing edge quality on fatigue samples for S550MC steel sheet.2026-26-0306To be published on 01/16/2026
The exceptional strength, formability, and weldability of S550MC steel sheets make them a cornerstone material in the automotive industry. These properties translate into the creation of high-performance automotive components like chassis parts, structural reinforcements, and safety cages, ultimately contributing to enhanced vehicle safety and overall performance. Furthermore, S550MC steel boasts excellent fatigue resistance, a critical factor for ensuring long-term reliability in demanding automotive applications that experience repeated stress cycles. However, beyond its inherent properties, optimizing the performance of S550MC components hinges on a nuanced understanding of the critical relationship between hole edge quality and fatigue failure. This meticulous study delves into the impact of hole-piercing clearance on the quality of the hole edges in modified fatigue samples manufactured from S550MC steel, and its effect on the fatigue life. The surface morphology was assessed
Nahalde, Sujay, Hingalje, Abhijeet, Ughade, Vikas, Singh, Udita, More, Hemant
Hydrogen Embrittlement in Galvanized High Carbon Steel Components of Automotive Seat Slider Assembly2026-26-0302To be published on 01/16/2026
This research paper investigates the failure of an isolator clip used in the seat slider assembly, which guides and restricts the sliding motion of the tooth bracket within the seat. The component is made of C80 high-carbon spring steel, known for its high strength. According to the manufacturing process details, zinc plating was applied to the component for corrosion protection, as confirmed by EDS analysis. A fractographic examination of the failed part revealed a brittle, intergranular fracture morphology with visible cracks. Certain areas also exhibited micro-void coalescence, indicating a dimpled fracture surface. The primary failure mode was intergranular (IG) fracture. The delayed fracture was attributed to intergranular fracture mechanisms, micro-void coalescence, and the high strength of the steel, which made the component susceptible to hydrogen embrittlement. Hydrogen embrittlement occurs when hydrogen atoms become trapped along the grain boundaries, where they form hydrogen
Saindane, Mehul Kishor, BALI, SHIRISH
Novel Approach on Material characterization Testing of various Wiring Harness2026-26-0548To be published on 01/16/2026
The automotive wiring harness (length of 4-5 km) is a very important and complex system in the development of a modern car due to a lot of new electric & electronic components and sensors. It is a very sensitive material unlike metals and is considered as a composite which is highly anisotropic in nature, as it consists of several different layers of copper/aluminum strands and insulation. Because of insulation, wiring harness exhibits viscous plastic behavior which is crucial in determining the durability and long-term performance of the cables. Material properties play an important role in determining the behavior of wiring harness after assembly into the car. Wiring harness may undergo Bending, Torsion and Tension loads, causing the stress and strain in the individual electrical wires. The lack of CAE validation of the wiring harness routing may lead to extra costs for the automotive OEMs over a period. This paper describes the novel method of Testing the Cables and Bundles used in
Beesetti, Siva, Kalkala Balakrishna, Prasad, James Aricatt, John, SHAH, Dipam, Tas, Onur, Krogmann, Stephan
Review on the flyback converter design for multi-output2026-26-0200To be published on 01/16/2026
With the increasing demand for DC loads, DC-DC converters have become indispensable in modern power electronic architectures. With high-voltage applications typical DC-DC converter topologies are required which include isolation for safety and voltage level conversion. Among various isolated converter topologies, the flyback converter is widely favored for low-power applications, typically under 100 W, due to its simplicity and cost-effectiveness. Like other DC-DC topologies, the flyback converter can operate in either continuous conduction mode or discontinuous conduction mode (DCM). The work have focused on the design and performance analysis of a flyback converter operating in DCM, with a specific emphasis on magnetic component design and loss evaluation. A 55 W multi-winding flyback converter employing a passive snubber circuit is studied and implemented. The loss analysis is done with switch losses around 3.4W and the coupled inductor core losses around 1.5W and copper losses
S, Denis, Deshpande, Prathamesh Pravin, Deshpande, Rohan
Life Cycle Assessment of Automotive Cables and GHG Emission Reduction Scenario in Indian Context2026-26-0240To be published on 01/16/2026
Globally, the emissions share of transport is 15%, out of which more than 2/3rd emissions are contributed by road transport as per 2014 report of Intergovernmental Panel on Climate Change (IPCC). The need of mitigation measures in transport sector has been realised however the study of life cycle emission needs to be done with the tailpipe emissions so that some holistic solution can be worked upon. Strikingly, in the life cycle studies of a passenger car, it was found that the share of raw materials related to copper is around 50% of the total amount of raw material used and the share of copper in the curb weight of vehicle is just 1%. Also, for an Internal Combustion Engine vehicle (ICE), mostly the copper is used in the wiring harness. In this paper, the life cycle assessment of wiring harness is done to understand the environmental impacts throughout the life cycle stages. The comparative study of aluminium alloy and copper has also been done to know the change in environmental
Kumar, Naman, Bawase, Moqtik, Thipse, Sukrut
Non-metallic inclusions in carburizing steels as a contributory factor for the formation of carbide net2026-26-0290To be published on 01/16/2026
The article deals with the issue of identifying structural defects that contribute to the formation of a carbide net during thermochemical treatment of steel parts, which negatively affects the mechanical properties complex of finished products. Based on the available data, a theory has been put forward regarding the influence of the present non-metallic inclusions in the carburizing steels structure on carbide formation process in the hardened layer. As an experimentally the samples have been produced from the varying chemical composition alloy structure carburized steel (0.17-0.23 % C, 0.17-0.37 % Si, 0.80-1.10 % Mn, 1.00-1.30 % Cr, 0.03-0.09 % Ti). During microstructure analysis of the samples it has been establish that non-metallic inclusions, in particular sulfides, contribute to the formation of carbides and carbide net in steel due to their high chemical activity with carbon. Thus, contamination of the metal of carburizing steels with non-metallic inclusions is not only a defect
Runova, Iuliia, Chatkina, Mariia, Musienko, Aleksandr
Niobium Alloyed Brake Disc for reduced NVH and emission control2026-26-0285To be published on 01/16/2026
Recent regulations limiting brake dust emissions have presented many challenges to the brake engineering community. The objective of this paper is to provide a low cost, mass production solution utilizing well known existing technology to meet brake emissions requirements. The proposed process is to alloy the Gray Cast Iron with Niobium. The Niobium addition will reduce wear debris and improve NVH (Noise Vibration Harshness). The test methodology included: Manufacture of disc samples alloyed with Niobium, and Evaluation of airborne wear debris utilizing a pin-on-disc tribometer equipped with emission collection capability. The airborne emission and wear surfaces were further analyzed by Scanning Electron Microscopy, Energy Dispersive techniques (SEM-EDS), X-Ray Diffraction and Optical Microscopy. The cast iron test matrix included four groups; Unalloyed eutectic 4.3% Carbon Equivalent (CE), Unalloyed hypereutectic >4.3% CE, Niobium alloyed Eutectic and Niobium alloyed hypereutectic
Barile, Bernardo, Holly, Mike
Balancing global and local formability properties through Nb microalloying2026-26-0303To be published on 01/16/2026
David Martin, CBMM Asia Bernardo Barile, CBMM Europe BV Caio Pisano, CBMM Europe BV Automotive high strength steels have specific microstructure-dependent forming characteristics. Global formability is generally associated with high uniform strain values which imply good drawability and stretch forming properties driven by pronounced work hardening. Local formability on the other hand is often measured by various fracture strain values—generally higher in single phase steels. In this respect, the so-called ‘local/global formability map’ concept has been established not only to provide a comprehensive methodology to characterize existing automotive steels but also to enable improvement strategies toward more balanced forming characteristics. Niobium (Nb) microalloying is a powerful tool to achieve both property improvement in general and property balance in particular. More than two decades of research has demonstrated that Nb-induced microstructural optimization is applicable to HSLA
Barile, Bernardo
Aluminum Alloy Castings, 7.0Si - 0.55Mg - 0.12Ti (F357.0-T6), Solution and Precipitation Heat TreatedAMS4289A (Current)11/19/2025
This specification covers an aluminum alloy in the form of castings (see 8.11).
AMS D Nonferrous Alloys Committee
Welded and Cold Drawn Low-Carbon Steel Tubing Annealed for Bending and FlaringJ525_202511 (Current)11/19/2025
This SAE Standard covers normalized electric-resistance welded, cold-drawn, single-wall, low-carbon steel pressure tubing intended for use as pressure lines and in other applications requiring tubing of a quality suitable for bending, flaring, forming, and brazing. In an effort to standardize within a global marketplace and ensuring that companies can remain competitive in an international market it is the intent to convert to metric tube sizes which will: Lead to one global system Guide users to preferred system Reduce complexity Eliminate inventory duplications
Metallic Tubing Committee
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
Santhana Babu, A.V., Antony Benson, B., Danusha, M.
Titanium Alloy Bars, Wire, Forgings, and Rings, 6Al - 4V, Extra Low Interstitial, AnnealedAMS4930M (Current)11/13/2025
This specification covers a titanium alloy in the form of wire, forgings, flash-welded rings 4.000 inches (101.60 mm), inclusive, and under in nominal diameter or distance between parallel sides, bars up through 10.000 inches (254 mm), inclusive, and under in nominal diameter with a maximum cross-sectional area for bars over 4.000 to 10.000 inches (101.60 to 254 mm) in diameter of 79 square inches (509.7 cm2), and stock for forging or flash-welded rings of any size (see 8.6).
AMS G Titanium and Refractory Metals Committee
Anodic Treatment of Titanium and Titanium Alloys, Solution pH 12.4 MaximumAMS2487C (Current)11/12/2025
This specification describes the engineering requirements for producing a non-powdery anodic coating on titanium and titanium alloys and the properties of such coatings.
AMS B Finishes Processes and Fluids Committee
“Reduction in Product Development Time by Field-To-Lab Simulation”2025-28-028211/06/2025
Puddling is a crucial process in rice cultivation, involving the preparation of the soil in a flooded field to create a soft, muddy seedbed. There are two classifications for puddling: full cage and half cage. Full cage puddling involves replacing the rear wheels of the tractor with steel paddle wheels, which are used to till the rice paddies directly without any additional implement. In the half cage puddling, the rear wheels remain on the tractor, and a smaller cage or paddle wheel is attached to the outside. Considering the field size, the operator often releases the clutch very quickly after a speed or direction change. This generates torque spikes, which are harmful to Transmission Gears and Clutches. This can lead to gear teeth bending fatigue failure due to repeated higher bending stresses. In this paper, a study related to how to reduce overall product development time by simulating bending fatigue failure of gear in lab environment is presented. A systematic approach is used
Pathan, Irfan Hamidulla, Bardia, Prashant
Steel, Corrosion-Resistant, Bars, Wire, Forgings, Rings, and Extrusions, 13Cr - 8.0Ni - 2.2Mo - 1.1Al (PH 13-8 Mo), Vacuum Induction Plus Consumable Electrode Melted, Premium Aircraft-Quality, Solution Heat Treated, Precipitation HardenableAMS5629K (Current)11/03/2025
This specification covers a premium aircraft-quality, corrosion-resistant steel in the form of bars, wire, forgings, flash-welded rings, and extrusions up to 12 inches (305 mm) in nominal diameter or least distance between parallel sides (thickness) in the solution heat-treated condition (see 8.4) and stock of any size for forging, flash-welded rings, or extrusions.
AMS F Corrosion and Heat Resistant Alloys Committee
Establishing the Method for Simulation of Electric Potential in Cooling Water Passages of Outboard Motors2025-32-000811/03/2025
Producing 3D models of cooling water passages of outboard motors, and calculating distribution of electric potential on the water passage surfaces using BEM, we have developed the new method for simulation of electric potential distribution. The outboard motor is a propulsion system attached to the transom of the boat with steering function. As the water around the boat is drawn in for cooling of the engine, the engine parts are susceptible to severe corrosion. As a means to help prevent corrosion, a part referred to as the anode metal, which has a lower natural potential, is provided. Such a method is called the sacrifice protection because the anode metal corrodes before the engine parts due to the difference of electric potential. Since anti-corrosion currents occur preferentially to areas close to the anode metal, the anode metal is required to be located at the most effective place for corrosion protection. However, there are certain restrictions in the layout of anode metal from
Shibuya, Ryota, Suzuki, Hiroki
A Simulation Approach for the Impact Assessment of an Axial Flux Traction Motor Applied on Road Electric Vehicle2025-32-007711/03/2025
In the transition towards sustainable mobility, Circular Design principles are crucial. Electric Motors are subject to continuous innovation to improve efficiency, performance density and reduce externalities associated with their production. Therefore, the choice of technological solutions during design phase must guarantee optimal performance and minimal environmental impact throughout the entire product life cycle: production, use, and end-of-life. In the automotive sector, the use phase is particularly critical since the efficiency of the traction system is directly related to total energy consumption during the life cycle and, consequently, to its environmental impact. This research introduces a simulation-based approach to evaluate the use phase of an Axial Flux Electric Motor equipped with Permanent Magnets (AFPM). While providing high performance for electric traction motors, these magnets are composed of Rare Earth Elements (REEs), e.g. Neodymium, classified as Critical Raw
Guadagno, Maurizio, Berzi, Lorenzo, Pugi, Luca, Delogu, Massimo
Development of High-Efficiency, Fully Recyclable eMotors for Light Mobility Applications Produced in the EU2025-32-009811/03/2025
This article presents a new generation of electric motors developed for light mobility and industrial applications. The motor range is based on synchronous reluctance technology using non-rare-earth permanent magnets. Three continuous power levels have been developed: 2, 4 and 6 kW. The challenges related to that motor range is their high continuous performances (cooled by natural convection) under nominal 48V, and reparability easiness without adding complexity. These motors stand out thanks to their competitive manufacturing cost and peak efficiency above 94%, which is a remarkable performance for this power and torque class. A prototype of a 6 kW continuous power has been produced and benchmarked. The experimental test showed a high level of correlation with the simulation calculation.
CISSE, Koua Malick, Milosavljevic, Misa, Mallard, Vincent, Valin, Thomas, De Paola, Gaetano
Steel, Corrosion-Resistant, Investment Castings, 16Cr - 4.1Ni - 0.28Cb (Nb) - 3.2Cu (17-4), Homogenization, Solution, and Precipitation Heat Treated (H1000), 150 ksi (1034 MPa) Tensile StrengthAMS5343G (Current)11/03/2025
This specification covers a corrosion-resistant steel in the form of investment castings homogenized, solution, and precipitation heat treated to 150 ksi (1034 MPa) minimum tensile strength.
AMS F Corrosion and Heat Resistant Alloys Committee
Higher-Strength, Higher-Toughness Die Cast Wheel Material using Recycled Aluminum2025-32-000711/03/2025
In an attempt to reduce CO2 release from alloy wheel production, we have developed an aluminum alloy for casting that satisfies necessary property requirements using recycled aluminum, but without heat treatment. The wheel is a critical safety feature of any vehicle, and it should have toughness and strength .In many wheels, virgin aluminum containing small amounts of impurities is used to maintain toughness, and heat treatment (T6), which is post-casting quick heating and quenching, is applied to provide strength. At the start of this project, we focused on two wheel-manufacturing processes, production of virgin aluminum and heat treatment, from which a large amount of CO2 is released. By switching to recycled aluminum, CO2 was reduced to one-ninth the original amount. The issue with recycled material is that impurities grow in the metal structures as intermetallic compounds and this reduces toughness. To deal with this issue, we have chosen high-pressure die casting (HPDC), in which
Suzuki, Noritaka
Alloy, Corrosion- and Heat-Resistant, Bars, Forgings, Rings, and Stock for Forgings and Rings, 21Cr - 20Ni - 20Co - 3.0Mo - 2.5W - 1.0(Cb+Ta) - 0.15N - 32Fe (N-155), Solution Heat TreatedAMS5769H (Current)11/03/2025
This specification covers a corrosion- and heat-resistant alloy in the form of bars, forgings, flash-welded rings, and stock for forging, flash-welded rings, or heading.
AMS F Corrosion and Heat Resistant Alloys Committee
Influence of Laser Sintered Process Parameters on Crystalline Characteristics and Mechanical Properties of AlSi10Mg Alloy05-19-03-001911/03/2025
The present study examines the influence of process parameters on the effect of strength and crystalline properties of AlSi10Mg alloy with laser sintered process. A detailed work was carried out with the effects of varying the laser power, scan speed, and hatch distance on crystalline structure, hardness, and surface roughness. From the analysis, the improved surface quality and mechanical performance were achieved with a scan speed of 1200 mm/s, a laser power of 370 W, and a hatch distance of 0.1 mm. An increase in hardness, improved surface finish, and reduced porosity was observed with decreased hatch distance. However, the balanced results were obtained for scanning speed of 1200 mm/s and laser power of 370 W. The ideal processing conditions decreased the crystalline size, increasing the overall material strength, when crystalline analysis was carried out. The higher scanning speeds supported improved grain refinement and heat diffusion, with the poor hardness value. With the lower
Shailesh Rao, A.
Optimization of Arc Welding Parameters for FB590 Hot-Rolled Ferritic-Bainitic Steel with 2.5 mm Thickness05-19-03-001810/31/2025
In this study, the optimization of robotic gas metal arc welding (GMAW) parameters for joining hot-rolled ferritic-bainitic FB590 steel sheets with a thickness of 2.5 mm was investigated. The main objective was to evaluate the effect of wire feed speed and welding speed on the penetration depth, throat thickness, and mechanical performance of the welded joint. A series of welding experiments were carried out with wire feed speeds ranging from 50 cm/min to 100 cm/min and welding speeds ranging from 5 cm/min to 15 cm/min. Tensile and microhardness tests were carried out to evaluate the structural integrity of the welded joints. The results show that increasing the wire feed speed significantly improves the weld penetration and throat thickness, especially at constant welding speeds. The most suitable combination was found to be 70 cm/min wire feed at 8 cm/min travel speed and 100 cm/min wire feed at 12 cm/min and 15 cm/min travel speeds. The microhardness in the heat-affected zone
Babir, Naime, Üzel, Uğur
Development of Temperature Sensor for Automotive2025-28-039410/30/2025
The work presents a micro-electromechanical system (MEMS) temperature sensor that has been designed using COMSOL Multiphysics 6.0 software for use in predicting the temperature of automotive parts. Due to its versatility, the shape of this design employs a meander, and this involves joule heating physics. It clearly shows the variation of resistance with temperature. For this design, Nitinol nano material is used because of the following advantages: Enhanced Shape Memory Effect, Superior Super elasticity, Increased Surface Area, Increased Surface Area, Improved Biocompatibility, Tunable Properties, Enhanced Mechanical Properties. Nitinol having high strength to weight ratio find its application in aerospace industry. This sensor works based on the principle of temperature dependence of resistance; that is, the resistance of the material increases or decreases based on temperature. It is observed that Nitinol has low von Mises stress, proving the safety nature of the material in
P, Geetha
Graphene Based Solar Photonic Battery for Aircraft-A Finite Element Based 2D Analysis2025-28-038910/30/2025
Over the past decade, significant progress in nano science and nanotechnology has opened new avenues for the development of high-performance photovoltaic cells. At present, a variety of nanostructure-based designs—comprising metals, polymers, and semiconductors—are being explored for photovoltaic applications. Advancements in the understanding of optical and electrical mechanisms governing photovoltaic conversion have been supported by theoretical analyses and modeling studies. Nevertheless, the high fabrication cost and relatively low efficiency of conventional solar photovoltaic cells remain major barriers to their large-scale deployment. One-dimensional (1D) nano materials, in particular, have introduced promising prospects for enhancing photovoltaic performance owing to their unique structural and electronic characteristics. Nanowires, nano rods, and nanotubes exemplify such 1D nanostructures, offering substantial potential to improve photon absorption, electron transport, and
P, Geetha, Sudarmani, R, c, Venkataramanan, Satyam, Satyam, Nagarajan, Sudarson
Development of Capacitive Pressure Sensor for Automotives2025-28-038710/30/2025
Measurement plays a crucial role in the precise and accurate management of automotive subsystems to enhance efficiency and performance. Sensors are essential for achieving high levels of accuracy and precision in control applications. Rapid technical advancements have transformed the automobile industry in recent years, and a wide range of novel sensor devices are being released to the market to speed up the development of autonomous vehicle technology. Nonetheless, stricter regulations for reliable pressure sensors in automobiles have resulted from growing legal pressures from regulatory bodies. This work proposes and investigates a tribo electric nano sensor that is affected by a changing parameter of the separation distance between the device's primary electrode and dielectric layers. The system is being modeled using the COMSOL multiphysics of electrostatics and the tribo-electric effect. Open circuit electric potential and short circuit surface charge density are two of the
P, Geetha, K, Neelima, Sudarmani, R, C, Venkataramanan, Satyam, Satyam, Nagarajan, Sudarson
Steel Bars, Forgings, Mechanical Tubing, and Forging Stock, 1.5Cr - 3.5Ni (0.07 - 0.13 C) (3310), Aircraft QualityAMS6250P (Current)10/23/2025
This specification covers an aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock.
AMS E Carbon and Low Alloy Steels Committee
Steel Bars, Forgings, Mechanical Tubing and Forging Stock, 1.2Cr - 3.2Ni - 0.12Mo (0.11 - 0.17C) (9315), Aircraft QualityAMS6263P (Current)10/23/2025
This specification covers an aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock.
AMS E Carbon and Low Alloy Steels Committee
Steel, Welding Wire 2.0Cr - 10Ni - 14Co - 1.0Mo - (0.13 - 0.17C) Vacuum Melted, Environment Controlled PackagingAMS6533D (Current)10/23/2025
This specification covers a premium aircraft-quality alloy steel in the form of welding wire.
AMS E Carbon and Low Alloy Steels Committee
Steel Bars, Forgings, Mechanical Tubing and Forging Stock, 0.92Cr - 0.75Ni - 0.52Mo - 0.003B - 0.04V (98BV40), Aircraft QualityAMS6423K (Current)10/23/2025
This specification covers an aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock.
AMS E Carbon and Low Alloy Steels Committee
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