Browse Topic: Metals

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TOPSIS-Based Multi-Criteria Optimization of WAAM Parameters for Automotive Component Fabrication2026-28-0026To be published on 02/12/2026
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
Sustainable Machining of Aluminium Alloys: Experimental Insights into WEDM Process Optimization2026-28-0034To be published on 02/12/2026
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
Evolution of a Novel Hybrid Stab-Link for a Born Electric Sports Utility Vehicle2026-28-0001To be published on 02/12/2026
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 02/12/2026
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
Modelling and Analysis of Complex Shaped Cracks2026-28-0048To be published on 02/12/2026
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
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 02/12/2026
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
Effect of Shot Peening on the Fatigue Life of Polylactic Acid Parts in Automobiles2026-28-0032To be published on 02/12/2026
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
Experimental Investigation of Process Parameter Effects in WAAM of Nickel-Based Alloys2026-28-0027To be published on 02/12/2026
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
Influence of Copper oxide and Graphite additives on the lubrication performance of the engine oil2026-28-0017To be published on 02/12/2026
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
AI-Driven Process Optimization in Wire Arc Additive Manufacturing of Nickel Alloys Using ANFIS2026-28-0025To be published on 02/12/2026
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
Parameter Optimization for Improved Surface Finish in WAAM-Fabricated Steel Structures2026-28-0023To be published on 02/12/2026
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
Optimization of machining parameters in drilling of carbon fiber reinforced aluminum sandwich composite using desirability function analysis2026-28-0097To be published on 02/01/2026
This study uses Taguchi-based DFA to optimize drilling of CFRP/Al sandwich composites. During drilling, high torque, thrust force, and severe delamination degrade the quality of CFRP/Al composites. In order to improve the sandwich laminates' quality, these responses must be tuned. These answers are therefore taken into account in the current study and optimized through the use of Taguchi-based Desirability Function Analysis. The composite desirability values derived from the desirability function analysis were used to evaluate the best machining settings, and analysis of variance (ANOVA) was used to determine the important contributions of each variable. It can be inferred from the results that the best outcomes were obtained.
Kala, K Lakshmi, Madhuri, K. Sudha, R L, Krupakaran, Tarigonda, Hariprasad
CFD Investigation of Heat Transfer in Aluminium Alloy Fins of Various Shapes2026-28-0105To be published on 02/01/2026
In an automobile industry, efficient heat dissipation is essential to maintain component performance and prevent material failure due to thermal stress. Fins, as extended surfaces, enhance heat transfer from hot surfaces to the surroundings through conduction and convection. Aluminum alloys are commonly used for fins due to their excellent thermal conductivity. This project focuses on the thermal analysis of four fins with different cross-sectional shapes: rectangular, circular, triangular and trapezoidal. The fins are modeled in ANSYS Workbench and thermal performance is evaluated using both ANSYS Workbench and ANSYS Fluent. Key parameters analyzed include temperature distribution, total and directional heat flux, temperature plots and thermal stress. The study aims to identify which cross-section provides the most efficient heat dissipation. It also explores how increasing fin surface area and quantity improves thermal performance. The findings will aid in optimizing fin design for
Sagaya Raj, Gnana
Analysis and Optimization of Drilling Parameters Using Desirability Function Analysis on Al70752026-28-0083To be published on 02/01/2026
This project aims to investigate the effect of carbide drill bits with different geometries on drilling 7075 Aluminum alloy (Al7075). The drilling on Al7075 will be performed by using CNC machine. The primary objective is to optimize drilling parameters to achieve better quality holes in Al7075, ensuring optimal assembly and product performance. The chosen input parameters for experimentation are spindle speed, feed rate, and tool geometry, while the selected output parameters are surface roughness, circularity error, and material removal rate. Three types of carbide drill bits twist, step, and Brad point are utilized for drilling Al7075. Machining trials involved drilling of holes on Al7075 according to L27 Taguchi’s orthogonal array (OA) approach using the solid carbide drill tools. Desirability function analysis has been used to find the effect, percentage contribution, and significance of the process parameters, namely, cutting speed, feed rate, drill bit type.The focus of this
Kala, Lakshmi K
Microstructural and Mechanical Characterization of AA6061-T6 Hybrid Composites Reinforced with SiC, Al₂O₃, and Mg via Sintering2026-28-0075To be published on 02/01/2026
In this research, the hybrid aluminum metal matrix composites (HAMMCs) were synthesized by using AA6061-T6 alloy as the matrix, reinforced with aluminum oxide (Al₂O₃), silicon carbide (SiC), and magnesium (Mg) through powder metallurgy and sintering processes. Four composite variants were synthesized with various percentages of reinforcement with a constant Mg content of 2 wt%. The materials were initially pot-milled, high-pressure pressed, and two-stage sintered in a nitrogen environment to promote uniform phase growth and minimum oxidation. Systematic study of reinforcement content influences on density, microstructure, and hardness was conducted. Microstructural studies indicated relatively homogeneous reinforcement particle distribution with occasional indication of agglomeration at high reinforcements. SEM and optical micrography confirmed improved bonding at low reinforcement levels and defects like voids and particle fractures in over-reinforced composites. Density analysis
R, Ganapathy Srinivasan, M, Selvam, pandian, Alagu, Ka, Harish, G cEng, Raghul
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
Calculation of Bending Capacity of L-Shaped Concrete Filled Steel Tube Special Column2025-99-0215To be published on 12/23/2025
In this paper, a systematic and in-depth study is carried out on the key engineering problem of the accurate calculation of the flexural capacity of L-shaped concrete-filled steel tubular columns. Based on the basic framework of mechanics theory, the basic design principle of reinforced concrete members is integrated, and the nonlinear characteristics of steel and concrete materials in the process of stress are mainly considered, such as steel yield strengthening, concrete compression damage, etc., and the ultimate bending moment calculation model which is more suitable for the actual stress state is constructed. Through rigorous theoretical derivation and multi-parameter comparative analysis, the final formula for calculating the bearing capacity of special-shaped columns not only has clear mechanical concept support, but also systematically defines the scope of application of the calculation method. The verification results show that the established calculation method not only meets
Wang, Cuicui, Bai, Shouyan, Wei, Hongxian, Lv, Shuang, Xu, Yafeng
Study on Seismic Performance of a Prefabricated CFST Bridge Pier2025-99-0204To be published on 12/23/2025
This paper investigates the seismic performance of the prefabricated concrete-filled steel tubular (CFST) bridge pier in the bridge system-level. The proposed prefabricated CFST bridge pier is composed of circular thin-walled CFST double-column, precast I-shaped tie beams, and precast RC cap beam, which are assembled by simply on-stie assembly connections, with advantages in good seismic performance, convenient construction, and comparable material cost. A total of 12 two-span continuous beam bridge cases are designed, including 2 typical bridges with reinforced concrete (RC) piers and 10 bridges with CFST piers. Numerical research on the hysteretic performance of piers in bridge cases, dynamic responses of all bridge cases, and their seismic fragility. The results demonstrate that prefabricated CFST piers outperform RC piers in both load-bearing capacity and energy dissipation, and these piers exhibit reduced transversal displacement at the top and decreased maximum curvature when
Gu, Chao, Wang, Xuanding
Study on Evolution of Surrounding Rock Stability and Structural Mechanical Behavior During In-Situ Expansion of Existing Tunnels in Weak Rock Mass2025-99-0207To be published on 12/23/2025
To address the escalating traffic demands and tackle the complex mechanical challenges inherent in in-situ tunnel expansion, this study, grounded in the Huangtuling Tunnel project in Zhejiang Province, China, focuses on the stability evolution of surrounding rock and the mechanical characteristics of structures during the in-situ expansion of existing tunnels under weak surrounding rock conditions. By systematically comparing core post-excavation features—such as surrounding rock displacement fields, ground pressure distribution pat-terns, and mechanical responses of support structures—between newly constructed tunnels and in-situ expanded tunnels, the research reveals key mechanical principles governing the construction of large-section tunnels in weak rock formations. Specifically, the findings are as follows: (1) Both newly constructed and in-situ expanded large-section tunnels exhibit significant spatial heterogeneity in surrounding rock deformation. The vault-spandrel zones serve
Zheng, Xiaoqing, Kang, Xiaoyue, Xu, Kai, Chen, Tao, Huo, Xinwang, Chen, Chuan
Fractographic Analysis after Creep Testing of Ti-6Al-4V with Yttria and Niobia Co-Doped Zirconia TBC2025-36-0053To be published on 12/18/2025
The application of Thermal Barrier Coatings (TBC) has been widely utilized in aerospace turbines to enhance the operational temperature and thermal efficiency of titanium alloys, while preserving their properties such as low density, creep resistance, and corrosion resistance. TBC systems typically consist of a metallic substrate, a metallic coating (Bond Coat), a thermally grown oxide (TGO), and a ceramic topcoat (TC). This study investigated the fracture surface characteristics of Ti-6Al-4V with TBC after a creep test at a constant temperature of 600 °C, under stress levels of 125, 222, and 319 MPa, in order to understand the mechanisms involved. The TBC was composed of a NiCrAlY (BC) and a zirconia co-doped with yttria and nióbia (TC). The fracture characterization of the alloy after the creep test was conducted through stereoscopy and scanning electron microscopy. The fracture mechanism at 600 °C and 222 MPa was predominantly ductile, as evidenced by the presence of dimples and
Takahashi, Renata Jesuina, de Assis, João Marcos Kruszynski, Rodrigues, Bianca Costa, de Andrade Acevedo Jimenez, Laila Ribeiro, Reis, Danieli Aparecida Pereira
Influence of Microstructure on the Mechanical Properties of Laser-Welded Joints between Different Classes of Automotive Steels2025-36-0049To be published on 12/18/2025
The need to reduce vehicle weight without compromising safety drives the use of advanced high-strength steels (AHSS) in the automotive industry. Laser welding is a widely employed technique for joining dissimilar materials due to its high precision and small heat-affected zone (HAZ). However, differences in the chemical composition and thermomechanical properties of the materials can create heterogeneous microstructures in the fusion zone (FZ) and HAZ, directly impacting the mechanical properties of the welded joint. This study aims to evaluate the relationship between microstructure and mechanical properties in laser-welded joints of dissimilar automotive steels. The objective is to understand how microstructural transformations affect weld strength, ductility, and toughness, contributing to process parameter optimization and improved structural performance. Microstructural analysis will be performed using optical microscopy, and mechanical tests, such as tensile testing and
Santos, dos Flávio Nunes, Reis de Faria Neto, dos Antonio, Dias, Erica Ximenes, Martins, Marcelo Sampaio, Santos Pereira, dos Marcelo
Development of a Localized Heat Treatment Route for Stamped Automotive Parts2025-36-0089To be published on 12/18/2025
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Santana, Jessica, Curti, Gustavo, Lima, Tiago, Sarmento, Matheus, Callegari, Bruna, Folle, Luis
Natural Fiber Composites with Nanomaterials: A Sustainable Alternative to Metals in the Automotive Industry2025-36-0040To be published on 12/18/2025
This paper analyzes the potential of combining natural fibers with nanomaterials to develop advanced composites for automotive sector applications, providing a sustainable alternative to parts traditionally produced with metallic materials. The metallic alloy in the automotive industry is widely used in vehicle manufacturing, but faces significant challenges, such as high production costs, high weight, susceptibility to corrosion, and rigorous recycling processes. Natural fibers stand out for favorable mechanical properties, low cost, low weight, and eco-friendly material, making promising alternatives to metals and synthetic fibers. The combination of natural fibers and nanomaterials creates composites with improved mechanical and thermal, reducing any limitations inherent to natural fibers. Therefore, composites combined, called hybrid, have a high potential for use in various automotive components, such as in structural and non-structural applications. This study also analyzes the
Corrêa, Karytha, Cabral, Gabriel, Santiago, Marcelo, Veloso, Verônica, Chaves, Matheus
Simulational and Experimental Validation with Structural Redesign of Bearing Housing in a Formula SAE Transmission System2025-36-0110To be published on 12/18/2025
The purpose of the study is to present the validation stages of the transmission bearing housings in a Formula SAE prototype and the redesign of the components to reduce mass. The objective was to design and implement bearing housings that are lightweight while withstanding the loads they are subjected to. A numerical simulation using the Finite Element Method (FEM) was conducted to analyze the behavior of the bearing housings, made of 7075 aluminum alloy, under the same boundary conditions as in the test bench. This simulation provided information on deformation and stresses and was used to determine optimal locations for strain gauge placement. Experimental bench tests were performed, applying forces ranging from 100 N to 600 N. With an application of a 600 N load, an experimental deformation of 1.77E-04 mm/mm was obtained, while FEM indicated 1.71E-04 mm/mm, demonstrating significant correlation, with a 3.4% margin of error. This pattern was observed for all loads, highlighting
Kopp, Amanda Fontoura, Hausen, Roberto Begnis, Martins, Mario Eduardo Santos
Research on Invasion Line Control of Deep Foundation Pit Diaphragm Wall Excavation Based on Space-time Effect2025-99-0316To be published on 12/17/2025
The study focuses on the management of deep foundation pit excavation, influenced by temporal and spatial factors, in the context of the challenging environmental circumstances posed by the high-water-level silty soft clay along the Yellow River's northern shore, as part of the Jinan urban rail transit initiative. The subsequent inferences have been made: (1) Throughout the digging phase, issues such as excessive digging and delays in installing steel reinforcements occur, while the subterranean diaphragm wall tends to shift significantly inward within the excavation area due to the disparity in pressure between the water and soil inside and outside. (2) During the building phase, managing wall distortion is imperative, and an enhanced preliminary force should be applied to the support's axial component at points of significant deformation, guaranteeing an excess coefficient for both the support rigidity and the continuous subterranean wall rigidity. (3) In the process of diaphragm
Gao, Tiangang, Zhang, Xu, Pan, Fuyong, Zhang, Wenjun
Reliability Simulation Analysis of Low Nickel Stainless Steel Carbody Structure2025-99-0323To be published on 12/17/2025
The demand for lightweight and cost-effective materials in rail transportation is increasing. Low nickel nitrogen austenitic stainless steel is considered a promising alternative for stainless steel car body structures because of its excellent mechanical properties and corrosion resistance. Due to the complexity and large scale of such structures, the structural reliability of car bodies made from this material is regarded as a critical concern. This issue is also addressed in the present study. Finite element analysis (FEA) is employed using ABAQUS to evaluate the structural performance of a low nickel stainless steel car body under various operational conditions. Based on the material specifications outlined in GB/T 7928-2003 “Stainless Steel for Urban Rail Transit Vehicles,” the structural design requirements of EN 12663-2010 “Railway Applications - Structural Requirements of Railway Vehicle Bodies,” and the experimental requirements of TB/T 3502-2018 “Modal Test Method and
Jiang, Long, Xie, Kun, An, Ziliang, Zuo, Yiwen
Lightweight Design and Optimization of Multi-Terrain Multi-Functional Tracked Amphibious Vehicle2025-99-0324To be published on 12/17/2025
In view of the complex intertidal terrain challenges faced by offshore wind power maintenance, this paper optimizes the lightweight design of multi-terrain tracked vehicles. The structure was optimized by finite element analysis, and the maximum stress was 211.68 MPa ( lower than the safety limit of 230 MPa), and the maximum deformation was 5.25 mm, which ensured the stability and stiffness. Titanium alloy has the advantages of high strength, low density and corrosion resistance, which improves the durability of the frame while reducing the weight of the frame. Advanced manufacturing technologies such as phase transformation superplastic diffusion welding optimize the connection between TC4 titanium alloy and stainless steel. Modal analysis and optimization techniques refine the structural parameters and improve the complex load performance. The research promotes the lightweight of the frame and provides theoretical and technical support for the design of multi-terrain vehicles.
Xu, Han, Xu, Shilin, Ma, Wenbo, Zhu, Wei
Study on the Mechanical Properties of a High-Strength Aluminum Alloy Profiles2025-99-0332To be published on 12/17/2025
Compared to steel, aluminum alloy has the advantages of light weight, high specific strength, corrosion resistance, and easy processing, and is widely used in structures such as aviation, construction, bridges, and offshore oil platforms. All along, Chinese construction aluminum profiles have been produced according to the GB/T5237-XXXX standard, which is determined based on the mechanical performance requirements of doors and windows and the actual processing of aluminum profiles. There are many problems. The author of this article has developed a new product 6063-T56, which has a tensile strength of 240-260Mpa and an elongation rate of not less than 8%, surpassing the latest technology level in Europe. It has been promoted and applied to the aluminum profile production industry in China, improving product performance, reducing production costs, improving production efficiency, and meeting the requirements of the "Aluminum Alloy Doors and Windows Standard" GB/T8478-2020, making
Qiao, Zhou
Analysis of Stress Behavior at the Arch Foot of a Spatial Double-Arch Composite Steel Box Arch Bridge2025-99-0340To be published on 12/17/2025
To assess the structural response of the steel-concrete composite joint in a long-span half-through spatial double-arch steel box arch bridge throughout its construction and service life, a comprehensive analytical approach was implemented. Initially, a global beam-element model was constructed using Midas Civil software to determine the structural response during critical phases, including the primary construction stage (Stage 1) and operational conditions. Subsequently, a refined local finite element model focusing specifically on the arch foot's steel-concrete interface was developed in Ansys. The modeling methodology incorporated experimental validation through field instrumentation data, enabling detailed examination of both stress distribution patterns within the composite zone and the fundamental force transfer principles at this critical structural transition. Key findings from this investigation demonstrate: When subjected to the combined effects of permanent and transient
Dong, Huili
Review of Through-the-Thickness Reinforcement Technologies Applied to Aircraft CFRP Composites2025-99-0355To be published on 12/17/2025
Carbon fiber-reinforced polymer (CFRP) composites are widely used in aircraft structures for weight reduction due to their high specific strength and modulus. However, their weak interlaminar properties lead to high sensitivity to out-of-plane loads such as impact, making them prone to delamination damage, which threatens flight safety. To enhance interlaminar performance, through-thickness reinforcement technologies, particularly Z-pinning and stitching, have become key research focuses. This paper systematically reviews the manufacturing processes, structural mechanical characteristics, and application progress in aerospace structures of these two mainstream through-thickness reinforcement technologies. Research shows that Z-pintechnology, by implanting metal or CFRP pins, and stitching technology, by sewing multiple fabric layers with fiber threads, both effectively bridge interlaminar cracks, significantly improving the impact resistance of composites. However, the implantation
Cui, Bo, Zhang, Yongjie, Zhang, Chuzhe, Jin, Tao
Nickel Alloy, Corrosion- and Heat-Resistant, Bars, Forgings, Rings and Stock for Forging, Rings and Heading, 65Ni - 15.8Cr - 15.2Mo - 0.30Al - 0.05La (HASTELLOY® S), Consumable Electrode Remelted, Solution Heat TreatedAMS5711G (Current)12/10/2025
This specification covers a corrosion- and heat-resistant nickel 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
The Simulation Study of Support Schemes for Transition Zones in Double-Fault Tunnels2025-99-044312/10/2025
When a tunnel passes through the transition zone between two faults, different support schemes have varying impacts on the deformation of the surrounding rock. This study, based on the Zhangzhuang Tunnel's double-fault area, establishes a numerical simulation model using Midas GTS NX to compare and analyze the effects of an enhanced support scheme versus a standard reinforcement scheme. The results indicate that when the non-reinforced support scheme is applied throughout the tunnel, the settlement of the transition zone's crown is 5.7 mm, only 0.27 mm greater than that of the reinforced scheme. Additionally, the variation in support stress in the transition zone between the two schemes is minimal. This demonstrates the feasibility of adopting the non-reinforced scheme, which reduces the number of steel arch frames, enhances construction efficiency, and provides a reference for future construction of small-section tunnels in double-fault conditions.
Wu, Jianmin, Niu, Shuo, Zhang, Te, Meng, Xianghua
Aerospace & Defense Technology: December 202525AERP1212/04/2025
High-Flying Output: Key Machining Techniques for Structural Aircraft Components Future-Proofing the Tactical Edge: Converging AI, Edge Processing, and Hybrid Cloud for Modern Battlefield Operations Digitally Transforming the Future of Defense: Collaborative Combat Aircraft How Lightweight Coatings Protect Aerospace and Defense Electronics How the US Space Force is Leveraging Commercial Antennas for Defense Applications German Researchers Test Quantum Channels In-Flight Researchers at the German Aerospace Center recently tested a quantum sensor in-flight on a Dornier 228 research aircraft. Novel Chromium-Molybdenum Metal Alloy Withstands Extreme Conditions A new high-temperature resistant material exhibits great potential for applications such as energy-efficient aircraft turbines. Electric Propulsion for a Nuclear-Powered Spacecraft Nuclear microreactors could improve the performance of electric propulsion systems in spacecraft. Controlling Heat Spikes in Electric Aircraft at Takeoff
Tolerances, Titanium and Titanium Alloy Extruded Bars, Rods, and ShapesAMS2245D (Current)12/01/2025
This specification covers established manufacturing tolerances applicable to titanium and titanium alloy extruded bars, rods, and shapes. These tolerances apply to all conditions, unless otherwise noted. The term “excl” applies only to the higher figure of the specified range.
AMS G Titanium and Refractory Metals Committee
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