In this paper, based on the cylindrical flow theory of incompressible viscous fluids and the equivalent circuit model of resonant sensing elements, a theoretical model for the measurement of liquid viscosity with a U-Shaped tungsten wire resonance sensor was established. This model can measure the liquid viscosity independently without liquid density or coupled detection of liquid density. The experimental results show that the decoupling of liquid viscosity and its density can be achieved at Re<1. The liquid viscosity is strongly linear with the resonant conductance. The viscosity measurement error is less than 7.24% in the viscosity range of 7.235cP to 85.2cP.

Shan, Baoquan, Shen, Yitao, Yang, Jianguo, Wu, Dehong

Fundamental Science on Oxygen Storage Capacity of Cerium Complex Oxides for Advanced On-Board Diagnostics (1) Kinetic Observation of Cerium Valence Change Using Synchrotron Radiation

2025-01-8474

04/01/2025

On-board diagnosis (OBD) of gasoline vehicle emissions is detected by measuring the fluctuations of the rear oxygen sensor due to the time-dependent deterioration of the oxygen storage capacity (OSC) contained in the automotive catalyst materials. To detect OBD in various driving modes of automobiles with an order of magnitude higher accuracy than before, it is essential to understand the OSC mechanism based on fundamental science. In this study, time-resolved dispersive X-ray absorption fine structure (DXAFS) using synchrotron radiation was used to carry out a detailed analysis not only of the OSC of ceria-based complex oxides, which had previously been roughly understood, but also of how differences in design parameters such as the type of precious metals, reducing gases (CO and H2), detection temperatures, and mileages (degree of deteriorations) affect the OSC rate in a fluctuating redox atmosphere. A fundamental characteristic was clearly demonstrated in ceria-based complex oxides

Tanaka, Hirohisa, Matsumura, Daiju, Uegaki, Shinya, Hamada, Shota, Aotani, Takuro, Kamezawa, Saeka, Nakamoto, Masami, Asai, Shingo, Mizuno, Tomohisa, Takamura, Riku, Goto, Takashi

Parameter Calibration Method of Johnson-Cook Constitutive Model based on Tensile and Compression Tests

2025-01-8242

04/01/2025

In new energy vehicles, aluminum alloy has gained prominence for its ability to achieve superior lightweight properties. During the automotive design phase, accurately predicting and simulating structural performance can effectively reduce costs and enhance efficiency. Nevertheless, the acquisition of accurate material parameters for precise predictive simulations presents a substantial challenge. The Johnson-Cook model is widely utilized in the automotive industry for impact and molding applications due to its simplicity and effectiveness. However, variations in material composition, processing techniques, and manufacturing methods of aluminum alloy can lead to differences in material properties. Additionally, components are constantly subjected to complex stress states during actual service. Conventional parameter calibration methods primarily rely on quasi-static and dynamic tensile tests, offering limited scope in addressing compression scenarios. This paper proposes an inversion

Kong, Deyu, Gao, Yunkai

Application of 1.7GPa Martensitic Steel in Dash Lower Cross Member to Enhance Automotive Frontal Impact Safety

2025-01-8218

04/01/2025

The rapid growth of electric vehicles (EVs) has led to a significant increase in vehicle mass due to the integration of large and heavy battery systems. This increase in mass has raised concerns about collision energy and the associated risks, particularly in high-speed impacts. As a consequence, crashworthiness evaluations, especially front-impact regulations, have become increasingly stringent. Crash speed between the vehicle and the Mobile Progressive Deformable Barrier (MPDB) is increasing, reflecting the growing emphasis on safety in the automotive industry. Moreover, a new frontal pole crash scenario is under consideration for future regulatory standards, highlighting the continuous evolution of crash testing protocols. To ensure occupant protection and battery safety, manufacturers have traditionally used Hot Blow Forming technology for producing closed-loop dash lower cross member components. However, this process is both costly and energy-intensive, necessitating more

Lee, Jongmin, Kim, Donghyun, Jang, Minho, Kim, Geunho, Seongho, Yoo, Kim, Kyu-Rae

Self-Piercing Riveting (SPR) of Magnesium High Pressure Die Casting and Dissimilar Materials

2025-01-8231

04/01/2025

Solid state joining processes are attractive for magnesium alloys as they can offer robust joints without the porosity issue typically associated with welding of magnesium and dissimilar materials. Among these techniques, Self-Piercing Riveting (SPR) is a clean, fast and cost-effective method widely employed in automotive industry for aluminum alloys. While SPR has been proven effective for joining aluminum and steel, it has yet to be successfully adapted for magnesium alloy castings. The primary challenge in developing magnesium SPR technology is the cracking of the magnesium button, which occurs due to magnesium's low formability at room temperature. Researchers and engineers approached this issue with several techniques, such as pre-heating, applying rotation to rivets, using a sacrificial layer and padded SPR. However, all these methods involve the employment of new equipment or introduction of extra processing steps. The aim of this work is to develop a SPR technique which adapts

Tabatabaei, Yousef, Wang, Gerry, Weiler, Jonathan

A DEM-FEM Coupled Analysis of Ultrasonic Shot Peening Dynamics and Surface Modification Parameters in Aluminum Alloys

2025-01-8239

04/01/2025

The significant mechanical features of aluminum alloy, including cost-effectiveness, lightweight, durability, high reliability, and easy maintenance, have made it an essential component of the automobile industry. Automobile parts including fuel tanks, cylinder heads, intake manifolds, brake elements, and engine blocks are made of aluminum alloy. The primary causes of its engineering failure are fatigue and fracture. Aluminum alloys' fatigue resistance is frequently increased by surface strengthening methods like ultrasonic shot peening (USP). This article discusses the shot peening dynamics analysis and the influence of ultrasonic shot peening parameters on material surface modification using the DEM-FEM coupling method. Firstly, the projectile motion characteristics under different processes are simulated and analyzed by EDEM. The projectile dynamics characteristics are imported into Ansys software to realize DEM-FEM coupling analysis, and the surface modification characteristics of

Adeel, Muhammad, Azeem, Naqash, Xue, Hongqian, Hussain, Muzammil

Research on Material Stress Strain Curve Prediction Methods Based on Transfer Learning and Artificial Intelligence

2025-01-8317

04/01/2025

The mechanical properties of materials play a crucial role in real life. However, methods to measure these properties are usually time-consuming and labour intensive. Small Punch Through (SPT) has non-destructive characteristics and can obtain load-displacement curves of specimens, but it cannot visually extract the mechanical properties of materials. Therefore, we designed a proprietary SPT experiment and fixture, built a finite element method (FEM) model and developed a multi-fidelity model capable of predicting the mechanical properties of steel and aluminium alloys. It makes use of multi-fidelity datasets obtained from SPT and FEM simulation experiments, and this integration allows us to support and optimize the predictive accuracy of the study, thus ensuring a comprehensive and reliable characterization of the mechanical properties of the materials. The model also takes into account variations in material thickness and can effectively predict the mechanical properties of materials

Zou, Jie, Chen, Yechao, Li, Shanshan, Huayang, Xiang

Image-Based Machine Learning Methods in Materials Microstructure and Failure Analysis

2025-01-8324

04/01/2025

Image-based machine learning (ML) methods are increasingly transforming the field of materials science, offering powerful tools for automatic analysis of microstructures and failure mechanisms. This paper provides an overview of the latest advancements in ML techniques applied to materials microstructure and failure analysis, with a particular focus on the automatic detection of porosity and oxide defects and microstructure features such as dendritic arms and eutectic phase in aluminum casting. By leveraging image-based data, such as metallographic and fractographic images, ML models can identify patterns that are difficult to detect through conventional methods. The integration of convolutional neural networks (CNNs) and advanced image processing algorithms not only accelerates the analysis process but also improves accuracy by reducing subjectivity in interpretation. Key studies and applications are further reviewed to highlight the benefits, challenges, and future directions of

Akbari, Meysam, Wang, Andy, Wang, Qigui, Yan, Cuifen

In-Situ Nanoindentation and Finite Element Analysis for Evaluating the Young’s Modulus of Anode Current Collectors in Lithium-ion Batteries

2025-01-8133

04/01/2025

As the utilization of lithium-ion batteries in electric vehicles becomes increasingly prevalent, there has been a growing focus on the mechanical properties of lithium-ion battery cores. The current collector significantly impacts the tensile properties of the electrode and the internal fracture of the battery cell. The stripping process tends to cause additional damage to the current collector, so tensile testing is not able to obtain in-situ mechanical properties of the current collector. Therefore, nanoindentation tests are required to acquire the in situ mechanical properties of the current collector. Nanoindentation testing represents the primary methodology for the determination of the mechanical properties of thin films. The Oliver-Pharr method is the standard approach used by commercial indentation instruments for the evaluation of mechanical properties in materials. Nevertheless, this approach is constrained by the limitations imposed by the sample boundary conditions. To

Dai, Rui, Sun, Zhiwei, Park, Jeongjin, Xia, Yong, Zhou, Qing

Thermomechanical Fatigue Behavior of Gray Cast Iron in Brake Rotors

2025-01-8319

04/01/2025

Gray cast iron is a cost-effective engineering material widely used for heavy duty engine blocks and brake rotor discs in vehicles. Thermomechanical fatigue (TMF) frequently occurs during vehicle operation due to temperature fluctuations in brake rotors. To speed up the design of the component, design structurally sounding brake rotors, and prevent premature thermally induced cracking, it is critical to investigate TMF behavior of the gray cast iron. This study presents a series of fatigue tests, including isothermal low cycle fatigue (LCF) tests at temperatures up to 700°C, as well as in-phase (IP) and out-of-phase (OP) TMF tests across various temperature ranges. Because of the asymmetric behavior in tension and compression, creep behaviors in both tension and compression and oxidation are also studied. These behaviors are the key to enable simulation of thermally induced cracks in rotors.

Liu, Yi, Lee, Heewook, Hess, Devin, Coryell, Jason

Material-Combined Vehicle Brake Disc Design for Enhanced Cooling Performance

2025-01-8189

04/01/2025

The improvement of heat dissipation performance of ventilated brake discs is vital to braking safety. Usually, the technical approaches shall be material optimization or structural improvement. In this paper, a simulation model of the heat transfer of brake discs is established using STAR-CCM+ software. Cast iron, aluminum metal matrix composite (Al-MMC), and carbon-ceramic composite materials (C-SiC) are compared. The results show that: Al-MMC has better thermal conductivity so that a more uniform temperature gradient distribution shall be formed; C-SiC has poorer heat capacity yet, according to previous studies, it has better thermal stability, which is the ability to ensure its friction factor under high-temperature condition; cast iron performs better with convective heat transfer rate, which enhances the heat transfer between the surface and surrounding flow field. Based on the results, this paper proposes four types of material combined brake discs using different friction

Wang, Jiarui, Jia, Qing, Zhao, Wentao, Xia, Chao, Yang, Zhigang

Fundamental Science on Oxygen Storage Capacity of Cerium Complex Oxides for Advanced On-Board Diagnostics (2) Quantitative Observation of Oxygen Released from Cerium Complex Oxides

2025-01-8476

04/01/2025

In order to comply with the tightening of global regulations on automobile exhaust gas, further improvements to exhaust gas control catalysts and upgrades to on-board diagnostics (OBD) systems must be made. Currently, oxygen storage capacity (OSC) is monitored by front and rear sensors before and after the catalyst, and deterioration is judged by a decrease in OSC, but it is possible that catalyst deterioration may cause the rear sensor to detect gas that has not been sufficiently purified. It is important to observe the activity changes when the catalyst deteriorates in more detail and to gain a deeper understanding of the catalyst mechanism in order to create guidelines for future catalyst development. In this study, we used a μ-TG (micro thermogravimetric balance) to analyze in detail how differences in design parameters such as the type of precious metal, detection temperature, and mileage (degree of deterioration) affect the OSC rate in addition to the OSC of the ceria-based

Hamada, Shota, Uegaki, Shinya, Tanabe, Hidetaka, Nakayama, Tomohito, Jinjo, Itsuki, Kurono, Seita, Oishi, Shunsuke, Narita, Keiichi, Onishi, Tetsuro, Yasuda, Kazuya, Matsumura, Daiju, Tanaka, Hirohisa

CONNECTOR ACCESSORIES, ELECTRICAL, BACKSHELL, STRAIGHT, SELF-LOCKING, SHIELD BAND TERMINATION (RFI/EMI), SHRINK BOOT ACCOMMODATION, CATEGORY 3B (FOR MIL-DTL-38999 SERIES I AND II CONNECTORS)

AS85049/85D (Current)04/01/2025

AE-8C1 Connectors Committee

Advanced Characterization of Mechanical and Cyclic Fatigue Properties of Aluminum Cast Materials for Optimized Industrial Applications

2025-01-8237

04/01/2025

Given the strategic importance of aluminum cast materials in producing lightweight, high-performance products across industries, it is fundamental to assess their mechanical and cyclic fatigue properties thoroughly. This investigation is primarily for optimizing material utilization and enhancing the efficiency and reliability of aluminum cast components, contributing to significant conservation of raw materials and energy throughout both the manufacturing process and the product's lifecycle. In this study, a systematic material investigation was conducted to establish a reliable estimation of the fatigue behavior of different aluminum cast materials under different loading ratios and elevated temperatures. This paper presents an analysis of the statistical and geometrical influences on various aluminum alloys, including AlSi10MnMg, AlSi7Mg0.3, and AlSi8Cu3Fe, produced via pressure die casting and gravity die casting (permanent mold casting), and subjected to different heat treatment

Qaralleh, Ahmad, Niewiadomski, Jan, Bleicher, Christoph

European Initiatives Addressing High Efficiency and Low-Cost Electric Motors for Circularity and Low use of Rare Resources

2025-01-8806

04/01/2025

The automotive industry is amidst an unprecedented multi-faceted transition striving for more sustainable passenger mobility and freight transportation. The rise of e-mobility is coming along with energy efficiency improvements, greenhouse gas and non-exhaust emission reductions, driving/propulsion technology innovations, and a hardware-software-ratio shift in vehicle development for road-based electric vehicles. Current R&D activities are focusing on electric motor topologies and designs, sustainability, manufacturing, prototyping, and testing. This is leading to a new generation of electric motors, which is considering recyclability, reduction of (rare earth) resource usage, cost criticality, and a full product life-cycle assessment, to gain broader market penetration. This paper outlines the latest advances of multiple EU-funded research projects under the Horizon Europe framework and showcases their complementarities to address the European priorities as identified in the 2Zero

Armengaud, Eric, Ratz, Florian, Muñiz, Ángela, Poza, Javier, Garramiola, Fernando, Almandoz, Gaizka, Pippuri-Mäkeläinen, Jenni, Clenet, Stéphane, Messagie, Maarten, D’amore, Lea, Lavigne Philippot, Maeva, Rillo, Oriol, Montesinos, Daniel, Vansompel, Hendrik, De Keyser, Arne, Romano, Claudio, Montanaro, Umberto, Tavernini, Davide, Gruber, Patrick, Ran, Liaoyuan, Amati, Nicola, Vagg, Christopher, Herzog, Matic, Weinzerl, Martin, Keränen, Janne, Montonen, Juho

Mitigating Paint Blistering Defects in Aluminum Casted Parts: A QC Story Approach Utilizing Computed Tomography

2025-01-8229

04/01/2025

Blistering in aesthetic parts poses a significant challenge, affecting overall appearance and eroding brand image from the customer's perspective and blister defects disrupt painting line efficiency, resulting in increased rework and rejection rates. This paper investigates the causes and effects of blistering, particularly in the context of internal soundness of Aluminum castings, emphasizing the crucial role of Computed Tomography in defect analysis. Computed Tomography is an advanced Non-Destructive Testing technique used to examine the internal soundness of a material. This study follows a structured 7-step QC story approach, from problem identification to standardization, to accurately identify the root Cause and implement corrective actions to eliminate blister defect. The findings reveal a strong link between internal soundness and surface quality. Based on the root cause, changes in the casting process and die design were made to improve internal soundness, leading to reduced

D, Balachandar, Nataraj, Naveenkumar

CONNECTOR ACCESSORIES, ELECTRICAL, BACKSHELL, 45°, SELF LOCKING, SHIELD, BAND TERMINATION, (RFI/EMI), SHRINK SLEEVE ACCOMMODATION, CATEGORY 3B (FOR AS50151 CRIMP, AS95234, MIL-DTL 26482 SERIES 2, AS81703 SERIES 3 AND MIL-DTL-83723 SERIES III CONNECTORS)

AS85049/83D (Current)04/01/2025

AE-8C1 Connectors Committee

Spray Characterization in a Constant Volume Chamber of Aluminum Oxide Nanoparticles-Diesel Blends

2025-01-8455

04/01/2025

Aluminum oxide (Al₂O₃) nanoparticles are considered a promising fuel additive to enhance combustion efficiency, reduce emissions, and improve fuel economy. This study investigates the spray characteristics of diesel fuel blended with aluminum oxide nanoparticles in a constant volume chamber. The blends were prepared by dispersing Al₂O₃ nanoparticles in diesel at varying concentrations (25, 50, and 100 mg of aluminum oxide nanoparticles into 1 L of pure diesel, respectively) using a magnetic stirrer and ultrasonication to ensure stable suspensions. Spray characterization was conducted in a high-pressure and high-temperature constant volume chamber, simulating actual engine conditions. The ambient temperatures for this experiment were set from 800 to 1200 K, and the oxygen concentrations were set from 21% to 13%. The study focused on key spray parameters such as spray penetration length, spray angle, and spray area, analyzed using high-speed imaging and laser diffraction techniques

Ji, Huangchang, Zhao, Zhiyu

Comparative Evaluation of Untextured and Textured Surfaces for Wear, Wettability and Friction Characteristics

2025-01-8331

04/01/2025

Reduction of frictional losses by changing the surface roughness in the form of surface textures has been reported as an effective method in reducing friction in the boundary regime of lubrication. Laser-based micro texturing has been mostly used to create these texture patterns and it is reported that it can reduce the frictional resistance by ~20-50%. However, the use of laser-based techniques for texture preparation led to residual thermal stress and micro cracks on the surfaces. Hence, the current study emphasizes using conventional micromachining on piston material (Al alloy Al4032) to overcome this limitation. Three variations of semi-hemispherical geometries were prepared on the surface of Al alloy with dimple depths of 15, 20 and 40 μm and dimple diameters of 90, 120 and 240 μm. Prepared textured surfaces with untextured surfaces are compared in terms of wear, wettability, and friction characteristics based on Stribeck curve behaviors. Results of this investigation demonstrated

Sahu, Vikas Kumar, Shukla, Pravesh Chandra, Gangopadhyay, Soumya

Material Characterization of Newly-Developed Advanced High Strength Steels for Prediction of Crash Performance

2025-01-8220

04/01/2025

New highly ductile advanced high strength steel (AHSS) grades with tensile strength greater than 980 MPa have been developed with the aim of achieving a combination of high strength and excellent formability. The new jetQTM-Family [1, 2] offers high local and global ductility, which is expected to contribute to the improvement of vehicle crash performance. For the reliable design and management of vehicle crash performance, material modeling, including work hardening behavior and material failure strain, plays an important role in numerical simulation. Especially, the accuracy of material failure prediction is important for the development of crash performance. In this study, the fracture behaviors of 980jetQTM, 1180jetQTM, and conventional Dual-Phase (DP) steels are investigated through simple tensile and V-bending fracture tests incorporating experimental-numerical hybrid ductile fracture analysis. Based on the experimental results, the ductile fracture parameters in the Hosford

Sato, Kentaro, Sakaidani, Tomohiro, Ohnishi, Yoichiro, Paton, Adrian, Roesen, Hartwig

Elevated Fracture Resistance of Q&P1180 Steel after Forming and Paint-Baking

2025-01-8221

04/01/2025

According to several precedent studies, most of the cold-forming advanced high-strength steel (AHSS) grades can obtain reinforced yield strength from the automotive forming and paint-baking treatments without losing their fracture resistance like some aluminum alloys. Concisely, the mechanism of such behavior can be mainly attributed to the ‘Cottrell Atmospheres,’ some thermally mobilized interstitial atoms that cluster around and impede mobile dislocations during only the yielding stage of the plastic deformation but cannot continue durably enough to affect the fracture. Nevertheless, an exception, Q&P1180, was discovered from precedent studies and characterized in this work. Different from other AHSSs, this grade exhibited distinctively elevated fracture resistance and yield strength after the pre-straining and baking. Such uniqueness was speculated to be caused by 1) no soft ferrite in the microstructure and 2) the transformed fresh martensite induced by the plastic deformation

Hu, Jun, Sun, Yeting, Thomas, Grant

A New Methodology to Characterize the Influence of Paint Baking and Pre-Straining on the Tensile Properties of Third Generation Advanced High Strength Steels

2025-01-8223

04/01/2025

The current ASTM A653 standard for determining the bake hardening index (BHI) of sheet metals can lead to premature fracture at the transition radius of the tensile specimen in high strength steel grades. In this study, a new test procedure to characterize the BHI was developed and applied to 980 and 1180 MPa third generation advanced high strength steels (3G-AHSS). The so-called KS-1B methodology involves pre-straining over-sized tensile specimens followed by the extraction of an ASTM E8 sample, paint baking and re-testing to determine the BHI. Various pre-strain levels in the range of 2 to 10% were considered to evaluate the KS-1B procedure with select comparisons with the ASTM A653 methodology for pre-strain levels of 2 and 8%. Finally, to characterize the influence of paint baking at large strain levels, sheared edge conical hole expansion tests were conducted. The tensile mechanical properties of the 3G steels after paint baking were observed to be sensitive to the pre-strain with

Northcote, Rhys, Berry, Avalon, Narayanan, Advaith, Tolton, Cameron, Lee, Haea, Smith, Jonathan, McCarty, Eric, Butcher, Cliff

A New Inverse Method for the Determination of Mechanical Properties of an Angle-Ply Composite Laminate by the CLPT

2025-01-8323

04/01/2025

Utilization of fiber-reinforced composite laminates to their full potential requires consideration of angle-ply laminates in structural design. This category of laminates, in comparison with orthotropic laminates, imposes an additional degree of challenge, due to a lack of material principal axes, in determination of elastic laminate effective properties if the same has to be done experimentally. Consequentially, there is a strong inclination to resort to the usage of “CLPT” (Classical Laminated Plate Theory) for theoretically estimating the linear elastic mechanical properties including the cross-correlation coefficients coupling normal and shear effects. As an angle-ply laminate is architecturally comprised of layers of biased orthotropic laminas (based on unidirectional or woven bidirectional fibers), an essential prerequisite for the application of CLPT is an a-priori knowledge of elastic mechanical properties of a constituent lamina. It is natural to expect that the properties of

Tanaya, Sushree, Deb, Anindya

Zero Circumferential Material Flow Line-Based Method for Reducing Stamping Simulation Cost

2025-01-8224

04/01/2025

In sheet metal simulation, computation time is significantly influenced by the number of elements used to discretize the sheet blank, which covers the shape of forming tool geometry. Based on particle kinematics, motion of material point is modeled, and the concept of zero circumferential motion material line (ZML) is proposed. The slope ratio of material line (SRML) is proposed to quantify the circumferential deviation for determining the ZML. Based on the SRML, a method is developed to segment sheet blank and apply constraints. The method is demonstrated through forming simulation on a Hishida geometry. The proposed method, with its minimal to no circumferential motion along ZMLs, exhibits high level of accuracy retention while simultaneously impressively reducing computation time (up to 77%). This combination of efficiency and precision makes it a compelling approach for reducing simulation cost.

Sheng, ZiQiang, Asimba, Brian, Cabral, Kleber

Establishment of Failure Simulation Models for Bonding of Carbon Fiber Laminated Skins and Cores in Monocoque Structures Based on Formula Student Racing Cars

2025-01-8006

04/01/2025

In Formula SAE , the primary function of the frame is to provide structural support for the different components and withstand the applied load. In recent years, most Formula Student teams worldwide to adopt monocoque made of carbon fiber composites, which are lighter and stronger. Enhancing the mechanical performance of carbon fiber laminates has been a key focus of research for these teams. In three-point bending tests, significant stress at the adhesive layer between the skin and the core material at both ends of the laminate, often lead to potential adhesive failure. Consequently, experimental boards often exhibit delamination between the outer skin and the core material, and premature core crushing, which compromises the mechanical performance of the laminate and fails to pass the Structural Equivalency Spreadsheet. Therefore, it is necessary to consider the influence of the bonding factor of toughened epoxy prepreg film on the mechanical properties of the laminated plate. This

Ning, Zicheng

Materials Innovation in Thermal Management: Advancing Aluminum Alloy Technologies for the Next-Generation Electrical Vehicle Battery Cold Plate

2025-01-8162

04/01/2025

The rapid expansion of the global electric vehicle (EV) market has significantly increased the demand for advanced thermal management solutions. Among these, the battery cold plate is a critical component, essential for maintaining optimal battery temperatures and ensuring efficient operation. As EV batteries increase in size, the thermal management requirements become more complex, necessitating the development of new alloys with enhanced strength and thermal conductivity. These advancements are crucial for the effective dissipation of heat and the ability to withstand the mechanical stresses associated with larger and more powerful batteries. The evolving performance demands of EVs are driving material innovation within the thermal management sector. This study aims to explore the global heat exchanger market trends from a material perspective, focusing on the evolution of the mechanical and thermal properties. Specifically, we investigated the transition from the traditional AA3003

Jalili, Mehdi, Wang, Xu, Razm-poosh, Hadi

Predicting Forming Limit of Hot Stamping Boron Steel Using a Modified Zener-Hollomon Parameter based Ductile Failure Criterion

2025-01-8225

04/01/2025

Combined with a modified Zener-Hollmon parameter, a recently proposed ductile failure criterion is further improved to predict the forming limit of boron steel at hot stamping temperatures. The ductile failure criterion takes into account the critical damage at localized necking or at fracture as a function of strain path and initial sheet thickness. The modified Zener-Hollomon parameter accounts for both effect of varying strain rate and temperature for Boron steel. Working FEM simulation, the capability of the ductile failure criterion is further demonstrated by predicting forming limit of a boron steel in an isothermal Nakajima dome test. Comparison shows the prediction matches quite well with the measurement.

Sheng, ZiQiang, Mallick, Pankaj

A Modified Johnson-Cook Model Considering Strain-Temperature Coupling for Welding Simulation of Aluminum Alloy Bumper

2025-01-8243

04/01/2025

The metal inert-gas (MIG) welding technique employed for aluminum alloy automotive bumpers involve a complex thermo-mechanical coupling process at elevated temperatures. Attaining a globally optimal set of model parameters continues to represent a pivotal objective in the pursuit of reliable constitutive models that can facilitate precise simulation of the welding process. In this study, a novel piecewise modified Johnson-Cook (MJ-C) constitutive model that incorporates the strain-temperature coupling has been proposed and developed. A quasi-static uniaxial tensile model of the specimen is constructed based on ABAQUS and its secondary development, with model parameters calibrated via the second-generation non-dominated sorting genetic algorithm (NSGA-II) method. A finite element simulation model for T-joint welding is subsequently established, upon which numerical simulation analyses of both the welding temperature field and post-welding deformation can be conducted. The results

Yi, Xiaolong, Meng, Dejian, Gao, Yunkai

3D Design and Analyses of an IC Engine Piston under Fatigue Test Conditions Using CNTs for the Next-Generation of Motorcycles

2025-01-8359

04/01/2025

CNTs play an important role in modern engineering projects, especially in engine pistons design for the next-generation of motorcycles. This work presents a comprehensive analyses proposed project using finite element method under actual operating conditions purpose performance evaluation of a motorcycle engine piston design, investigating the suitability of four distinct materials. Precise material properties adhering to linear elastic isotropic behavior were defined within the software environment and proposed advanced nanomaterial ensuring accurate representations of the proposed under the prescribed loading scenarios. The primary objective was to identify the optimal material choice for the piston, ensuring superior strength, minimal deformation, and lightweight characteristics essential for high-performance engine applications. Moreover interpreting and understanding the dynamic behavior of common and advanced engineering materials. Through a comprehensive evaluation of the

Ali, Salah H. R., Ahmed, Youssef G. A., Ali, Amr S.H.R.

Deformation Behavior and Springback Analysis of Anti-Collision Beam on Bending Forming

2025-01-8247

04/01/2025

Since aluminum alloys (AA) are widely used as structural components across various industries, higher requirements for shape-design, load-bearing, and energy-absorption capacity have been put forward. In this paper, we present the development of a numerical model, integrated with a compensation method, that effectively predicts processing defects in the bumper beam of a vehicle, resulting in a marked improvement in its forming quality. Specifically, different constitutive models are investigated for their applicability to the beam, enabling a precise evaluation of its structural performance under large deformation. The Johnson-Cook failure model is introduced to better characterize the fracture behavior of the beam under severe structural damage. The three-point bending experiment served as a rigorous examination, demonstrating good consistency between the experimental and simulation results. Furthermore, a prediction model for assessing the forming quality during the bending process

Zhang, Shizhen, Meng, Dejian, Gao, Yunkai

Understanding Forming Characteristics of Different Microstructure Steels within 980MPa and 1180MPa

2025-01-8222

04/01/2025

For electrical vehicle (EV) automotive body-in-white (BIW) structures, protection of passengers and battery in crash event becomes equally important. In addition to energy absorption, intrusion protection for battery and vehicle becomes extremely important and GPa advanced high strength steels (AHSS) including press hardened steels (PHS), DP/MP/CP/GEN3 steels have become material of choice for design for those components. Higher yield strength materials especially in 980/1180MPa MP and CP category are chosen for part design over conventional low yield strength DP. In this study, the forming characteristics including both global and local formability are evaluated and compared among 980 DP/MP grades. Formability test such as forming limit curve (FLC), true fracture strain, V bend, half dome, and hole expansion tests are conducted. Microstructure analysis to understand the effect of different grain structure and phases of DP/MP grades is also accomplished. A T-shape laboratory die trials

Shih, Hua-Chu, Pednekar, Vasant, Shi, Ming, Singh, Jatinder, Tedesco, Sarah, Wu, Wei

Fatigue Strength of Gray Cast Iron – New Insights Regarding the Size Effects

2025-01-8238

04/01/2025

Gray cast iron (GJL) is one of the oldest cast iron materials and is still in use in many applications in the automotive industry due to its good characteristics, in relation to lubrication, heat conductivity and damping. Engine parts particularly benefit from these parameters. Nevertheless, the design of these components has always been challenging, in terms of maximizing material utilization for lightweight designs for components under cyclic loading. In particular, with regard to the influence of the statistical (component size), geometrical (notches) and technological (microstructural) size effects, the existing guidelines and literature lack the necessary information to provide a comprehensive understanding of the cyclic material behavior of GJL materials. Within a comprehensive study, different GJL materials have been investigated at Fraunhofer LBF to provide more detailed information regarding the influence of size effects on fatigue strength. Accordingly, a variety of specimen

Bleicher, Christoph, Kansy, Axel

Evaluation of Additively Manufactured Thermoplastic Composite Magnetic Field Shielding for Stepper Motors

2025-01-8201

04/01/2025

As stepper motors become more and more widely used in engineering systems (vehicles, 3-D printers, manufacturing tools, and similar), the effects of their induced magnetic fields present a concern during the packing and orientation of components within the system. For applications requiring security, this is also a concern as the background electromagnetic radiation (EMF) can be captured at a distance and used to reproduce the motion of the motor during operation. One proposed alternative is to use customized non-magnetic plastic shields created using additive manufacturing. Some small studies have been completed which show some effectiveness of this approach but these studies have been small-scale and difficult to reproduce. To seek a more rigorous answer to this question and collect reproducible data, the present study used full factorial design of experiments with several replications. Three materials were used: Polylactide (PLA), PLA with 25% (weight) copper powder, and PLA with 15

Hu, Henry, Patterson, Albert E., Karim, Muhammad Faeyz, Porter, Logan, Kolluru, Pavan V.

Research and Structural Optimization of Lattice Core based on Monocoque of Formula Student Racing Car

2025-01-8003

04/01/2025

Monocoque is a kind of integrated shell structure technology, which has gradually become the primary choice for various racing teams to make car bodies because of its advantages of small specific gravity and high specific strength. The unit of the monocoque is a carbon fiber composite sandwich structure, which is composed of two layers of carbon fiber skin inside and outside and core material between them. The inner and outer layers of the carbon fiber skin are stacked with carbon fiber composite materials of different directions and types.In this project, we plan to optimize the shape of the monocoque shell using the surface design software Alias, select core materials of different materials and structures, more advanced layups, and obtain feasible layup sequences and core material types through Ansys simulation and Matlab collaborative optimization, which will be verified by three-point bending experiments. Different from the previous lightweight work based a lot on experience, this

Cheng, Zhu H., Liu, JJ

CONNECTOR ACCESSORIES, ELECTRICAL, BACKSHELL, STRAIGHT, SELF-LOCKING, SHIELD BAND TERMINATION (RFI/EMI), SHRINK SLEEVE ACCOMMODATION, CATEGORY 3B (FOR AS50151 CRIMP, MIL-DTL-26482 SERIES 2, AS81703 SERIES 3 AND MIL-DTL-83723 SERIES III CONNECTORS)

AS85049/82D (Current)03/31/2025

AE-8C1 Connectors Committee

Machine Learning–Based Modeling for Predicting the Lap Shear Strength of High-Strength Steel Laser Lap Welds

05-18-04-0029

03/29/2025

This study investigates the nonlinear correlation between laser welding parameters and weld quality, employing machine learning techniques to enhance the predictive accuracy of tensile lap shear strength (TLS) in automotive QP1180 high-strength steel joints. By incorporating three algorithms: random forest (RF), backpropagation neural network (BPNN), and K-nearest neighbors regression (KNN), with Bayesian optimization (BO), an efficient predictive model has been developed. The results demonstrated that the RF model optimized by the BO algorithm performed best in predicting the strength of high-strength steel plate-welded joints, with an R 2 of 0.961. Furthermore, the trained RF model was applied to identify the parameter combination for the maximum TLS value within the selected parameter range through grid search, and its effectiveness was experimentally verified. The model predictions were accurate, with errors controlled within 6.73%. The TLS obtained from the reverse-selected

Han, Jinbang, Ji, Yuxiang, Liu, Yong, Liu, Zhao, Wang, Xianhui, Han, Weijian, Wu, Kun

Aluminum Foil for Sandwich Construction

AMSA81596A (Current)

03/27/2025

This specification covers the requirements of uncoated aluminum alloy foil for core materials required for structural sandwich construction.

AMS D Nonferrous Alloys Committee

Aluminum Alloy, Extrusions, 4.4Cu - 1.5Mg - 0.60Mn (2024-T3510), Solution Heat Treated, Cold Worked, Stress-Relieved by Stretching, Unstraightened

AMS4164K (Current)

03/25/2025

This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing produced with cross-sectional area of 32 square inches (206 cm2), maximum (see 8.6).

AMS D Nonferrous Alloys Committee

Aluminum Alloy, Hand Forgings 8.0Zn - 1.0Cu - 1.6Mg - 0.12Zr (7037-T7452) Solution Heat Treated, Compression Stress Relieved, and Overaged

AMS4456B (Current)

03/25/2025

This specification covers an aluminum alloy in the form of hand forgings 11.000 inches (280 mm) and under in nominal thickness and of forging stock of any size (see 8.6).

AMS D Nonferrous Alloys Committee

BOLT, TEE HEAD, CHAMFERED - CRES, UNS S66286, 130 KSI MIN, .1900-32 UNJF-3A

AS9432C (Current)

03/25/2025

E-25 General Standards for Aerospace and Propulsion Systems

Aluminum Alloy, Rolled or Cold Finished, Bars and Rods, 12.2Si - 1.0Mg - 0.90Cu - 0.90Ni (4032-T651), Solution Heat Treated, Stress Relieved, Artificially Aged

AMS4319D (Current)

03/25/2025

This specification covers an aluminum alloy in the form of bars and rods 0.750 to 3.500 inches (19.05 to 88.90 mm), inclusive, in nominal diameter or least distance between parallel sides (see 8.5).

AMS D Nonferrous Alloys Committee

Steel Tubing, Seamless 0.15 Carbon Maximum (SAE 1010) Annealed

AMS5050M (Historical)

03/25/2025

This specification covers a low-carbon steel in the form of seamless tubing up to 5.50 inches (139.7 mm), nominal OD, inclusive.

AMS E Carbon and Low Alloy Steels Committee

Aluminum Alloy, Extrusions, 4.4Cu - 1.5Mg - 0.60Mn (2024-T3511), Solution Heat Treated, Cold Worked, Stress-Relieved by Stretching, and Straightened

AMS4165K (Current)

03/25/2025

This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing produced with cross-sectional area of 32 square inches (206 cm2), maximum (see 8.6).

AMS D Nonferrous Alloys Committee

BOLT, TEE HEAD, CHAMFERED - CRES, UNS S66286, 130 KSI MIN, .2500-28 UNJF-3A

AS9433C (Current)

03/25/2025

E-25 General Standards for Aerospace and Propulsion Systems

Classification of Common Imperfections in Sheet Steel

J810_202503 (Current)

03/25/2025

Common or obvious surface imperfections are normally visible to the naked eye before or after fabrication or processing. Illustrations and definitions of these imperfections are contained in this SAE Information Report. The identifying names are those commonly used throughout the steel industry. The imperfections identified include the major and most often encountered imperfections known to exist at this time. These imperfections are variable in appearance and severity. Extreme conditions have been selected in some instances in order to obtain suitable photographs. Photographs are courtesy of the American Iron and Steel Institute, Kaiser Aluminum, U.S. Steel, Nucor Steel, Samuel Steel, Steel Dynamics, Worthington Steel, and companies no longer in existence: LTV Steel, National Steel, and The Budd Company.

Metals Technical Committee

Steel, Corrosion- and Heat-Resistant, Welding Wire 15Cr - 25.5Ni - 1.3Mo - 2.2Ti - 0.006B - 0.30V (A286)

AMS5804J (Current)

03/25/2025

This specification covers a corrosion- and heat-resistant steel in the form of welding wire.

AMS F Corrosion and Heat Resistant Alloys Committee

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