Browse Topic: Metals

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Conceptual Design and Aerodynamic Configuration of the Relithia Nova: A 2000kg Hybrid-Electric STOL Aircraft2026-01-0660To be published on 07/01/2026
This paper presents the conceptual design of the Relithia Nova, a hybrid-electric Short Take-Off and Landing (STOL) aircraft engineered to provide essential connectivity to remote regions with limited aviation infrastructure, such as the South Pacific and Caribbean. Designed with a Maximum Take-Off Mass (MTOM) of 2,000 kg, the aircraft accommodates six occupants, including the pilot, and is optimized for operations on short, unprepared airstrips up to 2,000 ft elevation. The Relithia Nova employs a series-hybrid propulsion architecture featuring two wing-mounted turboshaft engines coupled with electric generators that drive propulsive rotors via a high-capacity lithium-ion energy storage system. This configuration ensures sustained power for high-lift generation while reducing emissions. Aerodynamically, the aircraft utilizes a high-aspect-ratio wing (AR=8.67) based on the NACA 23012 airfoil, chosen for its favorable lift-to-drag characteristics in subsonic flow (Mach 0.23 cruise
Chikwanha, Hendrick Tafadzwa
Electrical Harnessing in Satellite Launch Vehicles of ISRO – Methods for Sustainable, Safe, and Reliable systems2026-26-0779To be published on 06/01/2026
The electrical harness serves as the "neural network" for satellite launch vehicles, providing the interfaces for all guidance, health monitoring, and control systems during a mission. This system is composed of cables, and connectors. The wires are made of metallic conductors, typically copper plated with silver or gold to enhance conductivity and prevent oxidation. These conductors are insulated with polymeric materials such as PTFE, Kapton, ETFE, or TKT. Connectors, which are the interface points for electrical circuits, consist of gold or nickel-plated copper contacts housed within a shell. A typical launch vehicle contains an extensive network of electrical harnesses, with approximately 4,200 connectors and 110,000 meters of cable, which contributes to about 30% of the vehicle's total weight. The weight is mostly due to the polymeric insulation rather than the conductors. Challenges and Solutions for Sustainable Systems The paper highlights several key issues with current
K S, Nithish, TR, Binny, D S, Praveen Kumar
Predictive model and analysis of the resultant force in the dry machining of Mg-4Zn/Si3N4 nanocomposites2026-26-0762To be published on 06/01/2026
In aerospace and automotive applications, the usage of magnesium (Mg)-based alloys and composites reduces the structural weight due to their low density. They also possess good specific strength and are abundantly available. The Mg-4Zn alloy is one such Mg-based alloy that is also biodegradable and biocompatible. In spite of these advantages, there is a strong need and scope to improve its wear resistance and mechanical properties. Mg-4Zn nanocomposites with Si3N4 reinforcements (also a biocompatible bio-ceramic) are hypothesized to possess superior properties. Sustainable machining with minimal subsurface defects and minimal energy consumption is necessary to manufacture components from these vacuum stir-cast nanocomposites. The resultant machining force (Fr) is a good indicator of subsurface quality and energy consumption in machining. The addition of Si3N4 reinforcement to improve the properties of the Mg-4Zn alloy could introduce challenges in machining and could influence Fr. To
N, Anand, Shaju, Tony M, G, Nagamalleswara Rao, D, Bijulal, K, Jayaprakash Reddy, K, Vijayan, Chaman, Joji J
Wear Resilience Characteristics of 2% Silicon Nitride Strengthened AZ31 Magnesium Composite2026-26-0740To be published on 06/01/2026
To develop magnesium matrix composites, ceramic silicon nitride (Si3N4) particles are used to strengthen the magnesium (AZ31) matrix by adding 2 wt.%. The composite is developed by disintegrated melt deposition vacuum stir casting method. Microstructural studies reveal the presence of Si3N4 particles and their uniform distribution. A L9 orthogonal array planned using Taguchi’s experimental design is chosen for three wear parameters axial load (AL), rotational speed (RS), and time duration (TD) for trials as per G99 standard in pin-on-disc apparatus. Experimental outcomes show a rise in axial stress; wear loss increases dramatically. Because the area of contact shrinks as sliding speed increases, wear loss diminishes dramatically. When the AL is low, CoF increases, and when the AL is large, CoF drops. When the sliding speed is increased, CoF decreases. To optimize multiple responses effectively, the TOPSIS method (Technique for Order of Preference by Similarity to Ideal Solution) was
Senthilkumar, N., Dhinakar Raj, C K
Reducing Test Campaigns through Advanced Yield Surface Modeling for New Aircraft Metal Grades2026-26-0755To be published on 06/01/2026
Qualification of new aerospace alloys requires extensive mechanical testing to capture anisotropy and ensure reliable performance under complex loading conditions. This process is costly and time-consuming, particularly with emerging manufacturing routes such as additive manufacturing. Advanced yield surface prediction offers a route to reduce test campaigns by linking microstructural features to macroscopic constitutive models. In this work, Digimat is employed as a multi-scale material modeling platform to generate yield surfaces of polycrystalline metals using computational homogenization. Representative volume elements (RVEs) are constructed from experimental texture and grain morphology data, and their response under multiaxial loading is simulated using a crystal plasticity framework. The computed yield loci are then fitted with phenomenological functions (e.g. Barlat2000), enabling calibration of anisotropic yield models from virtual testing. As a case study, an AA6016-T4 sheet
Padhan, Manas, Uppaluri, Rohith, Lemoine, Guerric, Soni, Ganesh
Investigation of Aluminium Alloy Composites Reinforced with Zirconium oxide and Solid Lubricant Attributes for Brake and Clutch Components of Aircrafts2026-26-0752To be published on 06/01/2026
For brake and clutch components of aircraft, which require higher mechanical strength and wear resistance, lightweight aluminum composites were developed by infusing solid lubricant. In this study, hybrid composites were developed using the powder metallurgy route, using aluminum alloy AA356 and various amounts of zirconium oxide (ZrO₂) (0, 5, 10, 15, and 20 wt.%) as reinforcements. A solid lubricant, hexagonal boron nitride (hBN), at a fixed 5 wt.% is considered. Following the appropriate ASTM guidelines, the specimens were mechanically characterized by measuring their density, porosity, micro-hardness, compression strength, impact strength, and flexural strength, among other properties. The findings showed that the composites' physical and mechanical behaviour were greatly affected by the addition of ZrO₂.Porosity increased as a result of particle clustering and interfacial voids, while density increased gradually as ceramic content increased. Consistently increasing ZrO₂ addition
Senthilkumar, N.
Lightweight Magnesium Nanocomposites with Enhanced Wear Resistance for Landing Gear Application2026-26-0751To be published on 06/01/2026
This study systematically evaluated the wear behaviour of an AZ61 magnesium alloy reinforced with 15 wt.% SiC and different amounts of multi-walled carbon nanotubes (MWCNTs) under dry sliding circumstances, adopting a pin-on-disc apparatus (ASTM G99). To identify the influence of factors like sliding speed (SS) (1-3 m/s), axial load (AL) (10-30 N), and MWCNT concentration (0-3 wt.%) on tribological performance, experiments were developed using a Central Composite Design (CCD) under Response Surface Methodology (RSM). Findings showed that wear loss (WL) was greatly amplified by increasing AL owing to localized heating and contact stresses, and that a compacted tribolayer was formed by increasing SS, which decreased WL but marginally raised the coefficient of friction (CoF). At moderate AL (15-20 N), SS (2 m/s), and 2 wt.% MWCNT, the wear resistance was significantly improved by improving load transfer and creating a lubricating carbon-rich coating, resulting in a decreased WL of around
Senthilkumar, N.
Aluminum Alloy, Extruded Profiles (2065-T84), 4.2Cu - 1.2Li - 0.52Mg - 0.32Mn - 0.32Ag - 0.1Zr, Solution Heat Treated, Stress Relieved by Stretching and Artificially AgedAMS4366B (Current)4/21/2026
This specification covers an aluminum-lithium alloy in the form of extruded profiles with a maximum cross-sectional area of 19 square inches (123 cm2) and a maximum circle size of 11 inches (279 mm) from 0.040 to 0.499 inch (1.00 to 12.50 mm) in thickness (see 8.6).
AMS D Nonferrous Alloys Committee
Steel Bars, Forgings, Mechanical Tubing and Forging Stock, 1.2Cr - 3.25Ni - 0.12Mo (0.07 - 0.13C) (9310), Premium Aircraft-Quality, Electroslag Remelted or Consumable Electrode Vacuum RemeltedAMS6267L (Current)4/21/2026
This specification covers a premium aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock.
AMS E Carbon and Low Alloy Steels Committee
Aluminum Alloy, Hand Forgings, 6.2Zn - 2.3Cu - 2.2Mg - 0.12Zr (7050-T7452), Solution Heat Treated, Compression Stress-Relieved, and OveragedAMS4108G (Current)4/21/2026
This specification covers an aluminum alloy in the form of hand forgings 8 inches (203 mm) and under in nominal thickness and of forging stock (see 8.6).
AMS D Nonferrous Alloys Committee
Copper-Beryllium Alloy, Bars, Rods, Shapes, and Forgings, 98Cu - 1.9Be, Solution Heat Treated (TB00)AMS4650P (Current)4/21/2026
This specification covers a copper-beryllium alloy in the form of bars, rods, shapes, and forgings (see 8.5).
AMS D Nonferrous Alloys Committee
Investigation of Metallurgical and Mechanical Behaviors of AA6061-AA2017 Joints Produced by Single- and Double-Pass Friction Stir Welding: Influence of Base Material Position and Post-Weld Shot Peening Technique05-19-04-00264/13/2026
The growing demand for lightweight, high-strength materials in marine and aerospace structures has promoted the use of friction stir welding (FSW) for welding dissimilar aluminum alloys. However, tensile residual stresses and microstructural heterogeneities often degrade weld integrity. This study investigates the combined impact of base material positioning, single- and double-pass FSW, and post-weld shot peening (SP) on the metallurgical and mechanical properties of AA6061–AA2017 joints. Five welding configurations were examined to evaluate how varying base material positions on the advancing and retreating sides affect material flow and mechanical behavior. Post-weld SP effectively presented compressive residual stresses, reduced surface defects, and refined surface grains. The average grain size in the stir zone was reduced from 5.2 μm (single-pass) to 2.0 μm (double-pass U-turn) after SP, confirming significant grain refinement through dynamic recrystallization. Mechanical testing
Nukathoti, Raja Sekhar, Battina, N. Malleswara Rao, Vanthala, Varaha Siva Prasad, Chirala, Hari Krishna, Maloth, Balu
Steel, Corrosion-Resistant, Bars, Wire, Forgings and Forging Stock, 18.5Cr - 10Ni - 0.22Se (303Se), Free-Machining; for Swaging or Upsetting, Solution Heat TreatedAMS5641K (Current)4/13/2026
This specification covers a free-machining, corrosion-resistant steel in the form of bars, wire, forgings, and forging stock.
AMS F Corrosion and Heat Resistant Alloys Committee
Nickel Alloy, Corrosion- and Heat-Resistant, Sheet, Strip, and Plate, 45.5Ni - 25.5Cr - 3.2Co - 3.2Mo - 3.2W - 18.5Fe, (RA333®), Solution Heat TreatedAMS5593J (Current)4/13/2026
This specification covers a corrosion- and heat-resistant nickel alloy in the form of sheet, strip, and plate.
AMS F Corrosion and Heat Resistant Alloys Committee
Steel, Corrosion-Resistant, Investment Castings, 16Cr - 1.9Ni - 0.08N (431), As CastAMS5353G (Current)4/13/2026
This specification covers a corrosion-resistant steel in the form of investment castings.
AMS F Corrosion and Heat Resistant Alloys Committee
Titanium Alloy Bars, Wire, Forgings, and Rings, 6Al - 6V - 2Sn, AnnealedAMS4978K (Current)4/13/2026
This specification covers a titanium alloy in the form of bars, wire, forgings, flash-welded rings 4.000 inches (101.60 mm) and under in diameter or least distance between parallel sides, and stock of any size for forging or flash-welded rings (see 8.6).
AMS G Titanium and Refractory Metals Committee
Nickel Alloy, Corrosion- and Heat-Resistant, Bars, Forgings, Rings and Stock for Forgings, Rings and Heading, 72Ni - 15.5Cr - 0.95Cb - 2.5Ti - 0.70Al - 7.0Fe (Inconel® X750), Equalized, Precipitation HardenableAMS5667R (Current)4/13/2026
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
Steel, Corrosion- and Heat-Resistant, Sheet, Strip, and Plate, 15Cr - 25.5Ni - 1.2Mo - 2.1Ti - 0.006B - 0.30V (A286), Multiple Melted, 1800 °F (982 °C) Solution Heat Treated, Welding Grade, Precipitation HardenableAMS5858F (Current)4/13/2026
This specification covers a corrosion- and heat-resistant steel in the form of sheet, strip, and plate.
AMS F Corrosion and Heat Resistant Alloys Committee
Magnesium Alloy, Investment Castings, 8.7Al - 0.70Zn - 0.22Mn (AZ91C-T6), Solution and Precipitation Heat TreatedAMS4452G (Current)4/9/2026
This specification covers a magnesium alloy in the form of investment castings (see 8.6).
AMS D Nonferrous Alloys Committee
Steel Bars, Forgings, and Tubing, Nitriding, 1.4Cr - 1.2Mo - 0.3V (0.29 - 0.36C), (32CrMoNiV5), Double Vacuum Melted, Premium Aircraft-Quality for Bearing ApplicationsAMS6498C (Current)4/9/2026
This specification covers a nitriding grade of premium aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock. AMS6496 and AMS6497 cover UNS K23280 with other quality levels.
AMS E Carbon and Low Alloy Steels Committee
Aluminum Alloy, Rolled or Forged Rings, 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr (7075-T651, 7075-T652), Solution Heat Treated, Mechanically Stress Relieved, and Precipitation Heat TreatedAMS4310G (Current)4/9/2026
This specification covers an aluminum alloy in the form of rolled or forged rings up to 6 inches (152 mm), inclusive, in thickness (see 3.3.1.1.1) and an OD to wall thickness ratio of 10 or greater (see 8.5).
AMS D Nonferrous Alloys Committee
Magnesium Alloy, Investment Castings, 9.0Al - 2.0Zn (AZ92A-T6), Solution and Precipitation Heat TreatedAMS4453H (Current)4/8/2026
This specification covers a magnesium alloy in the form of investment castings (see 8.6).
AMS D Nonferrous Alloys Committee
Steel, Sheet, Strip, and Plate, 0.75Si - 0.62Cr - 0.20Mo - 0.10Zr (0.10 - 0.17C) (NAX 9115-AC)AMS6354H (Current)4/8/2026
This specification covers a low-alloy steel in the form of sheet, strip, and plate 4.00 inches (101.6 mm) and under in thickness.
AMS E Carbon and Low Alloy Steels Committee
Copper Alloy (Brass), Sheet, Strip, and Plate, 70Cu - 30Zn, Half Hard (H02)AMS4507K (Current)4/8/2026
This specification covers a copper-zinc alloy (brass) in the form of sheet, strip, and plate (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet, 3.2Cu - 0.52Mg - 0.30Ag - 0.95 Li - 0.12Zr (2198-T8), Solution Heat Treated, Cold Worked, and Artificially AgedAMS4412C (Current)4/8/2026
This specification covers an aluminum alloy in the form of sheet from 0.063 to 0.249 inch (1.60 to 6.30 mm) in nominal thickness (see 8.6).
AMS D Nonferrous Alloys Committee
Characterization of a Low-Cost Insulator Substrate for Traction Power Modules2026-01-01194/7/2026
Demand for cost-effective automotive traction inverters requires improved power module packaging. This paper presents a packaging method using an epoxy composite insulator applied directly to the cold plate surface, replacing Direct Bonded Copper (DBC) and Active Metal Brazed (AMB) substrates. This integration removes the substrate-to-cold plate solder interface and eliminates two material layers from the thermal path. The epoxy composite demonstrates a dielectric strength greater than 60 kV/mm. Thermal resistance (junction-to-coolant) measured approximately 0.17 K∙cm2/W. Electrical characterization showed a relative permittivity of 3.9, which is lower than standard ceramics and results in reduced parasitic capacitance. Initial thermal cycling tests indicated no significant degradation in thermal or electrical performance. These results suggest the epoxy composite insulator could be a promising alternative for traction power modules.
Chen, Yu, Mena-Garcia, Javier, Chen, Hao, Xiao, Kewei, Gupta, Man Prakash, Degner, Michael
High Strain Rate Behaviors of Fiber Reinforced Composites in Principal and Off-Axis Directions2026-01-01754/7/2026
Materials can exhibit significantly different mechanical behaviors compared to quasi-static conditions at high strain rates (> 100 s-1). High strain rate tests using setups such as SHPB (Split-Hopkinson Pressure Bar) can provide, in a practicable manner, the stress-strain relations for a material at high strain rates. Such properties are vitally needed for activities such as simulation-driven impact safety design of composite structures deployed in the form of automotive body parts and assembly, and other sub-systems. Although the behaviors of isotropic and ductile materials such as various metallic alloys appear to have been extensively studied and reported in literature, dependence of mechanical properties of fiber-reinforced composites especially in different off-axis directions are extremely difficult to come across. To fill up this void, a detailed experimental study has been carried out on high strain rate mechanical characterization of a laminated orthotropic glass/epoxy
Bawa, Prashant, Deb, Anindya, Barui, Ananya, Zhu, Feng
Effective Prediction of the Mechanical Properties of Glue-Laminated Motor Stator Core with Consideration of Glue Disposition2026-01-01774/7/2026
This study presents an effective predictive methodology for determining the mechanical properties of glue-laminated motor cores, with explicit consideration of glue disposition, including bonding pattern, configuration, location, and coverage. In laminated stator cores, glue bonding and stacking processes jointly govern the mechanical integrity of the lamination stack. Practical production bonding schemes are typically nonuniform and localized, leading to spatial variations in stiffness and to locally anisotropic, orthotropic material behavior. These effects influence both the in-plane and through-thickness stiffness of the stator core. They can significantly affect the accuracy of structural simulations, such as NVH responses of high-speed traction motors and e-drive systems. Given the constituent material properties of the electrical steel laminations and the glue, this work distinguishes the governing mechanisms underlying the equivalent core properties. The in-plane stiffness is
Nie, Zifeng
A Study on Fatigue Life Prediction Method for Point-Based Joints Considering Multiple Fracture Modes – FDS, Blind Rivet, and Blind Nut Focus2026-01-01804/7/2026
The application of multiple materials in vehicle bodies is accelerating as the adoption of lightweight aluminum alloys and composite materials advances rapidly. These materials play a crucial role in reducing overall vehicle weight, enhancing fuel efficiency, and complying with increasingly strict environmental regulations. As the automotive industry continues to evolve toward electrification and sustainability, the integration of lightweight and high-performance materials has become a key design strategy. However, the use of multiple materials creates new challenges in manufacturing, particularly for joining technologies. Since different materials have varying mechanical properties, thermal behavior, and surface characteristics, the selection of appropriate joining methods is essential for ensuring structural integrity and durability. Depending on material types, thicknesses, production processes, and cost constraints, various joining techniques—such as mechanical fastening, welding
Takuno, Sougo, Isono, Toshiyuki, Urakawa, Kazushi, Goto, Suguru, Kawamura, Hiroaki, Niisato, Eita, Ishigami, Yuta
Machine Learning-Based Prediction of Tensile Properties in Cast Stainless Steel Influenced by Chemical Composition Variation2026-01-02374/7/2026
In the category of cast stainless steels, there are several variants per different level of addition of chromium, vanadium along with some minor elements, such as molybdenum, niobium, tungsten to meet the requirement of corrosion and oxidation resistance. However, the influence of chemical composition variations on the mechanical properties of cast SS continues to lack a clear understanding. In the present study, via machine learning, the effects of each element on the tensile properties of the selected cast stainless steel are studied. The machine learning model is then used to predict how variations in elements affect tensile behavior, with the predictions validated through physical testing.
Mishra, Neelam, Biswas, Surjayan, V S, Rajamanickam, Aluru, Phani, Liu, Yi, Akbari, Meysam, Coryell, Jason
Tensile and Fatigue Behavior of High Pressure Die Cast AE44 Magnesium Alloy at Elevated Temperatures2026-01-02344/7/2026
Tensile and cyclic behavior of high pressure die cast AE44 magnesium alloy have been studied at room temperature and elevated temperatures up to 350°C. Anelastic behavior has been found in both tensile and cyclic loading at the temperature below 200°C. With increasing temperature, the anelasticity disappears, and tensile and cyclic behaviors become like other engineering materials, such as steels and aluminum alloys, i.e. the total strain contains only elastic strain and plastic strain. A method to determine the yield strength at 0.2% plastic strain (σ0.2) is proposed. By using the proposed method, the yield strength σ0.2 is found to be higher than that determined using the traditional method, which is more suitable to the materials that do not exhibit anelasticity. It is believed that the anelasticity is closely related to twinning in Mg alloy, which disappears at elevated temperatures.
Liu, Yi, Yang, Wenying, Coryell, Jason
Multi-Material Topology Optimization Using Difference-Based Equivalent Static Load Method2026-01-01734/7/2026
Topology optimization (TO) has become a powerful tool for generating lightweight structural designs. TO has been widely applied to linear static problems, where analytical sensitivities are easy to obtain. However, crashworthiness design requires nonlinear dynamic analysis, for which analytical sensitivities are generally not available. To extend TO into crash problems, approximation methods such as the Equivalent Static Load (ESL) method have been developed. ESL replaces the nonlinear problem with a series of linear static subproblems, ensuring that the displacement fields match at certain time steps. These subproblems can then be efficiently solved using standard TO techniques. A key limitation of ESL is that it relies on the initial mesh for all subproblems, which reduces accuracy for highly nonlinear crash responses. To address this, Triller proposed the difference-based ESL (DiESL) method, which updates the mesh in each subproblem to the deformed configuration, therefore improving
Huang, Yuhao, Kim, Il Yong
Lightweight Bubble Sheet Panel To Reduce Inverter Noise and Vibration for Electric Vehicles2026-01-04424/7/2026
Inverters are typically integrated into electric drive units for electric vehicles (EVs) to reduce packaging size and cost. However, coupled vibrations from the electric motor and gears are transmitted to the inverter, which can become a dominant noise source due to its large radiative panel. Metal panels are required for electromagnetic interference (EMI) compliance, yet these covers usually lack sufficient stiffness or damping for noise control. Adding ribs and applying damping treatments result in excessive mass, cost, and packaging challenges. A new bubble sheet panel design has been developed to enhance the structural strength and damping performance of the inverter cover while significantly reducing its mass. A thin sheet of aluminum is welded onto the cover in an optimized pattern that enhances stiffness and damping performance while accommodating packaging requirements. The welding pattern can include logos or artistic designs to improve the panel’s appearance. The metal sheets
He, Song, Bobel, Andrew, Naismith, Gregory, Yi, Wenwen, Patruni, Pavan Kumar
Role of Advanced Polishing Techniques in Enhancing Al-Cu Diffusion Bonding for EV Application2026-01-02354/7/2026
The demand for lightweight, high-efficiency components in electric vehicles (EVs) highlights the critical need for reliable Al-Cu joints with superior electrical and thermal conductivity. While diffusion bonding has emerged as a promising approach, interfacial impurities and voids often degrade joint quality and conductivity. Conventional manual polishing was initially employed to prepare Cu and Al surfaces; however, this method proved insufficient in consistently removing oxides and contaminants, leading to non-uniform bonding. In addition, the larger surface area of the samples made traditional polishing impractical, further motivating the use of electropolishing. To overcome these limitations, we introduce electropolishing pretreatment to achieve cleaner, void-free interfaces. Electropolishing effectively dissolves surface asperities and contaminants, enabling intimate atomic contact during bonding and minimizing the formation of brittle intermetallic phases. A systematic
Abbasi, Hossein, Liu, Yi, xiao, Yaohong, Wang, Andy, Su, Jinrong, Wang, Qigui, Chen, Lei
Comparison of Formability Performance Between CR550LA and CR590DP2026-01-01784/7/2026
While rapid development of advanced high strength steels (AHSS) for a safer and lighter vehicle has been a primary focus in the automotive industry, the application of traditional high strength low alloy (HSLA) steel continues to be actively supported and developed. AHSS are often used to replace HSLA steels for downgauging while maintaining similar or better performance in crashworthiness and durability. However, recent developments have enabled the availability of higher strength, cold-rolled HSLA steels that could offer opportunities for a more balanced solution between material cost and material performance. Certain higher strength HSLA steels not only offer a cost-effective way to increase the strength-to-weight ratio but also provide comparable formability and better weldability to AHSS. In this study, cold rolled HSLA grades of CR420LA and CR550LA are evaluated in overall formability and in-use performance when compared to CR590 dual phase (DP) grade. The evaluations performed
Shih, Hua-Chu, Brown, Lindsay, Pednekar, Vasant, Shi, Ming, Tedesco, Sarah
Effects of Temperature and Mechanical Load on Li-Ion Battery Aging: Insights from Multi-Rate Reference Performance Test2026-01-03834/7/2026
As the utilization of lithium-ion batteries in electric vehicles expands, monitoring the usable cell capacity (UCC) is essential for ensuring accurate state-of-health (SOH) estimation. Battery performance degradation is influenced by temperature and constraints. Capacity tests in laboratory settings are typically conducted at low C-rates to approximate equilibrium conditions, whereas in real vehicle applications, charging currents are often much higher. This discrepancy in rates frequently results in deviations between laboratory characterization and on-board Battery Management Systems (BMS) capacity estimation. To investigate how C-rate of diagnostic Reference Performance Test (RPT) modulates aging effects under temperature and mechanical loading, we conducted long-term cycling tests on lithium iron phosphate/graphite pouch cells at 25°C and 45°C under different constrained conditions. The cycling protocol is a tiered multi-rate protocol. Cells were aged at Block1 under 1C, and UCC
Zhang, Shan, Niu, Zhice, Xia, Yong
Optimizing Joint Efficiency in Stainless Steel-Aluminum Alloy FSW Joints through Advanced Parameter Control2026-01-02284/7/2026
The present study investigates optimization of ultimate tensile strength (UTS) in FSW of AA2024-T3 and SS304 in a butt joint configuration. An L18 mixed-level orthogonal array was used to design 18 experiments, varying tool rotational speed (450, 560, and 710 rpm), traverse speed (20, 25, and 40 mm/min), and pin offset (1 and 1.5 mm toward the Al side). The tool rotational speed had the greatest influence on UTS, contributing nearly one-third of the total variance, followed by pin offset and traverse speed. The optimal combination, 450 rpm, 20 mm/min, 1.5 mm offset, yielded a UTS of 344.7 MPa and a joint efficiency of 78.3%. At this setting, peak temperatures reached ~356 °C, ensuring sufficient plasticization and uniform mixing of the Al–SS interface, producing a refined stir zone with an average grain size of 4.2 μm. Fracture analysis revealed ductile failure at the optimal parameters, whereas suboptimal conditions resulted in brittle or mixed fractures due to either insufficient or
Mir, Fayaz Ahmad, Khan, Noor Zaman, Pali, Harveer Singh
Design and Simulation Analysis of an Integrated Honeycomb-Filled Front Bumper for a Special Vehicle2026-01-04754/7/2026
In frontal collisions of automobiles, the bumper beam at the front of the vehicle plays a crucial role in absorbing energy and protecting the vehicle body during a collision. To enhance the collision resistance of a specific type of special vehicle with a non-load-bearing body structure, this paper focuses on this type of vehicle and conducts a study on the design and collision performance of an integrated vehicle front bumper - anti-collision beam structure based on aluminum alloy additive manufacturing technology. A novel bumper structure is proposed, which integrates the front bumper and the front anti-collision beam of the vehicle and is integrally formed using aluminum alloy additive manufacturing technology. This integrated structure is directly connected to the vehicle frame. Firstly, based on the appearance of the special vehicle body and the form of the front anti-collision beam of traditional passenger vehicles, an integrated design of the vehicle front bumper- anti-collision
王, Xufan, Yuan, Liu-Kai, Zhang, Tangyun, Wang, Tao, Zhang, Ming, Wang, Liangmo
Investigation on Microstructure and Mechanical Properties in the Dissimilar Joining of WE43 to AA7075 Alloy using FSW2026-01-02294/7/2026
This research investigates the alterations in microstructure, microhardness, and joint strength resulting from the dissimilar friction stir welding (FSW) of WE43 magnesium alloy to AA7075 aluminium alloy. The study specifically analyses the role of FSW process parameters in the formation of intermetallic compounds (IMCs), the evolution of grain structure, the resultant microhardness distribution across the weld zone, and the joint tensile strength. A comprehensive microstructural characterization was performed utilizing optical microscopy (OM), field emission scanning electron microscopy with energy-dispersive X-ray spectroscopy (FESEM-EDS), electron backscatter diffraction (EBSD), and X-ray diffraction (XRD). These analyses confirmed significant grain refinement in the stir zone and the identification of various IMCs at the weld interface. Microhardness mapping indicated a gradient profile, with the weld nugget exhibiting superior hardness attributed to its dynamically recrystallized
Ahmad, Tariq, Khan, Noor Zaman, Ahmad, Babar, Siddiquee, Arshad Noor
Advancing Sustainable Electric Vehicles: A Simulation-Driven Study on Rare Earth-Free Motors and Battery Technologies2026-01-02424/7/2026
The increasing adoption of electric vehicles (EVs) introduces critical vulnerabilities associated with dependence on rare earth elements used in traction motors and battery systems, impacting supply chain stability, environmental sustainability, and cost scalability. This investigation focuses on simulation-optimized rare earth-free EV propulsion components, including induction-based and wound rotor electric motors employing ferrite and iron-nitride magnetic materials, in combination with lithium iron phosphate (LFP) battery chemistry recognized for enhanced safety and extended cycle life. An integrated multi-physics simulation framework coupled with targeted experimental validation is employed to evaluate efficiency, thermal behavior, and durability of the proposed motor–battery systems. The optimized configurations demonstrate automotive-grade performance, with motor efficiencies ranging from 90–96% and LFP batteries retaining over 84% of nominal capacity after 5,000 charge–discharge
Saraswat, Shubham, Vishe, Prashant
Strain-Based Fracture Assessment of Tailor Welded Blanks under Complex Loading Conditions2026-01-02314/7/2026
Tailor Welded Blanks are critical for automotive lightweighting yet prone to premature failure due to differential thickness and strength across the weld. This study utilized digital image correlation (DIC) to analyze the maximum in-plane principal Hencky strain (E₁max) and axial strain (εₐₓₐₗ) of TWBs under complex loading conditions, including biaxial and plane-strain states. Twelve distinct material stack-ups were tested to evaluate the impact of material difference on formability. Results indicated that differential properties significantly altered strain distribution, often forcing localization onto the thinner or softer sheet. While UHSS welds provided high load capacity with limited ductility, combinations using HSLA or IF substrates were susceptible to early localization and unstable fracture. Comparative heatmaps illustrate strain evolution across all samples, providing spatial insights beyond conventional force–displacement analysis. Metallurgical characterization confirmed a
Aminzadeh, Ahmad, Sheng, ZiQiang, Huang, Lu, McCarty, Eric, Biro, Elliot
NASA Tech Briefs: April 202626AERP044/2/2026
Leonardo DRS Expands Production Capacity to Advance Naval Power, Sensors, and AI-Driven Mission Systems Success at Sea: NIWC Atlantic Uncrewed Surface Vessel Completes Fastest Transatlantic Crossing High‑Speed Spindles Unlock Five‑Axis Machining Innovation with Smaller Tools Why CFD is Stuck in the File Era Accurate and Resilient GNSS Timing Modules for Critical Infrastructure Undetectable Ship-to-Ship Laser Communications EP40: Structural Epoxy Used for Steel Bonding in Marine Applications Master Bond EP40 is a two-part, room temperature curing epoxy for bonding, sealing, coating, and encapsulating. EP40 bonds well to a variety of substrates, including naval steel, the primary structural metal used in the shipbuilding industry Vortex Research to Solve Aviation's Efficiency Tradeoff with Active Strakes A research team developed a smart strake system that dynamically adapts to flight conditions, showing a promising drag reduction in the wind tunnel with respect to passive strakes. This
Advancing Steel Joining: A Critical Review of Adhesives and Sealants for High-Performance Automotive and Construction Applications05-19-04-00253/31/2026
For centuries, steel has been a cornerstone material for structural construction; by contrast, adhesive joining is a relatively nascent technology, particularly in heavy structural applications. The present article aims to provide the reader a review of the applications of adhesive joining in steel-based applications. Steel being a popular material in many industries due to its excellent mechanical properties, but traditional joining methods might have certain limitations viz. ability to withstand vibrations or movement, distortion, difficult to repair, and the like. Adhesive joining provides an alternative approach that offers advantages like reduced weight, improved corrosion resistance, enhanced aesthetics, ability to join multi-materials, ability to resist vibrations to a certain limit, and the like. This article examines the use of steel within the automotive and construction industries, intentionally narrowing its scope from steel’s broader range of applications. This article
S., Shrray, Arora, Kanwer Singh
BOLT, MACHINE - HEXAGON HEAD, PD SHANK, NICKEL ALLOY (UNS N07001), .1900-32 UNJF-3AAS3303B (Current)3/30/2026
E-25 General Standards for Aerospace and Propulsion Systems
Columbium (Niobium) Sheet, Strip, and FoilAMS7850F (Current)3/25/2026
This specification covers columbium in the form of sheet, strip, plate, and foil.
AMS G Titanium and Refractory Metals Committee
Castings, Leaded Bronze, Sand and Centrifugal, 80Cu - 10Sn - 9.5Pb, As CastAMS4842H (Current)3/25/2026
This specification covers a leaded bronze in the form of sand and centrifugal castings (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Welding Wire, 7.0Si - 0.52Mg (357)AMS4246G (Current)3/25/2026
This specification covers an aluminum alloy in the form of welding wire.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet, 3.5Cu - 1.1Li - 0.50Mg - 0.40Ag - 0.12Zr (2098-T8), Solution Heat Treated, Cold Worked, and Artificially AgedAMS4457B (Current)3/25/2026
This specification covers an aluminum alloy in the form of sheet 0.125 to 0.249 inch (3.18 to 6.32 mm), inclusive, in nominal thickness (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Rolled or Cold-Finished, Bars, Rods, and Wire, and Flash-Welded Rings, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061; -T6, -T651)AMS4117M (Current)3/25/2026
This specification covers an aluminum alloy in the form of rolled or cold-finished bars, rods, and wire and of flash-welded rings and stock for flash-welded rings.
AMS D Nonferrous Alloys Committee
Copper-Zinc Alloy, Laminated Sheet, 70Cu - 30Zn, Surface BondedAMS4508K (Current)3/25/2026
This specification covers a copper-zinc alloy (brass) in the form of laminated sheet with nominal thickness 0.006 to 0.125 inch (0.15 to 3.18 mm) (see 8.5).
AMS D Nonferrous Alloys Committee
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