Browse Topic: Metals

Items (33,767)
Find
Drilling Methods for Controlling Exit Burr Height in CRES Material Stacks2025-01-0169To be published on 04/25/2025
The Electroimpact Automatic Fan Cowl Riveter uses two novel drill processes to control exit burr height and achieve the required hole quality in CRES (Corrosion-Resistant Steel, also called stainless steel) material stacks. Both processes use piloted cutters on the OML side, and two different tools are used in a backside spindle on the IML side of the component. The first process uses a shallow-angle shave tool in the IML spindle to directly control the exit burr height after it is produced by the OML spindle and is called the “burr shave” technique. The second process uses a countersink tool in the IML spindle and produces an “intermediate countersink” after the pilot hole is drilled by the OML spindle, but before the final hole diameter is drilled. These drill processes were able to achieve the required hole quality in a challenging CRES material stack, which allows the machine to be qualified for one-up assembly of the component.
Schultz, Rich, Peterman, Randy, Luker, Zachary, Murakonda, Sai Krishna
Technical Paper
Image Processing-Based Chip Detection by KIZKI Algorithm and Its Optimization2025-01-0168To be published on 04/25/2025
The process of producing aircraft parts involves the drilling of aluminum alloys. This creates a large amount of chips, which are removed using air, but sometimes they still remain within the holes. This is checked by inspectors through visual inspection. However, the quality of human inspection varies based on skill level and fatigue. Thus, image-based inspection should be used to stabilize and further improve inspection quality. This study aims to build a framework for chip detection based on image processing. Taking into account on-site implementation, the system must have low installation and running costs and be standalone. Therefore, we adopt the KIZKI algorithm, which satisfies these conditions. KIZKI means awareness in Japanese. This is a model of human peripheral vision and saccades. It does not require training like AI and can achieve high-speed and high-performance detection using a low-performance computer. In other words, there is no need for a computer with an expensive
Iinuma, Marin, Sato, Junya, Tsuji, Masahiko
Technical Paper
Novel Stainless Steel Substitutes Aerospace Titanium Alloys2025-01-0167To be published on 04/25/2025
Titanium is a critical production material for the aerospace and defense industries, and in recent years many aerospace companies have been suffering from titanium shortage in the world market. To find a long-term solution for that problem, AMD Corp. proposes a new material - Novel stainless steel - as a low-cost substitution of the high strength titanium alloys commonly used in the aerospace. The steel possesses the same or higher specific strength (a ratio of strength to density) compared to the specific strength of the commercial Ti-6Al-4V alloy at the same ductility, toughness. Corrosion resistance of Novel stainless steel approaches the corrosion resistance of 15-5PH grade. Novel stainless steel can be utilized for high-temperature (>500℃) applications, while Ti-6Al-4V alloy is limited to <500℃. Another advantage of HSCR steel is better workability and machinability compared to the Ti-6Al-4V alloy. Utilizing the Novel stainless steel offers the following benefits: • Reduces
Vartanov, Gregory
Technical Paper
A New Test Rig for Electrically Actuated Landing Gear and Brake of a Small Transport Aircraft2025-01-0161To be published on 04/25/2025
Performing highly representative tests of aircraft equipments is a critical feature for gaining utmost confidence on their ability to perform flawlessly in flight under the entire spectrum of operating conditions. This can also contribute to accelerate the certification process of a new equipment. A research project (E-LISA) was performed in recent years, as part of the european funded Clean Sky 2 framework, with the objective of building an innovative facility for testing an electrically actuated landing gear and brake for a small air transport. The project eventually led to the development and construction of an Iron Bird able to reproduce in a realistic and comprehensive way a full variety of landing test cases consistent with certification specifications and landing histories available in the repository of the airframer. The Iron Bird that was eventually developed is a multi-functional intelligent and easy reconfigurable facility integrating hardware and software allowing to
De Martin, Andrea, Jacazio, Giovanni, Bertolino, Antonio
Technical Paper
Research and structural optimization of lattice core based on monocoque of Formula Student racing car2025-01-8003To be published on 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 Hypermesh simulation and Matlab collaborative optimization, which will be verified by three-point bending experiments and circumferential shear experiments. Different from the previous
Cheng, Zhu H., Liu, JJ
Technical Paper
Fundamental science on oxygen storage capacity of cerium complex oxides for advanced on-board diagnostics (2) Quantitative observation of oxygen released from cerium complex oxides2025-01-8476To be published on 04/01/2025
In recent years, increasingly stringent emissions regulations have forced automakers to further improve emission control catalysts and to upgrade on-board diagnostics (OBD). For gasoline-powered vehicles, OBD detects the degradation of the oxygen storage capacity (OSC) of the automotive catalysts over time, but the detection limits are becoming stricter. Therefore, we conducted research to gain a deeper understanding of OSC in catalysts. In general, cerium complex oxides (ceria) releases oxygen from the crystal lattice into the gas phase due to the change in valence in oxidizing and reducing atmospheres, as shown in the following formula. (formula) Ce^(4+) O_2 ⇄〖Ce^(4+)〗_(1-x) 〖Ce^(3+)〗_x O_(2-x/2) + (x/4) O_2 In this study, we directly quantified the amount of oxygen released from the ceria crystal lattice under various reducing gas conditions and temperatures using a micro thermogravimetric analyzer (μ-TG) that can measure as small as 1 μg (1 × 10^-6 g). In addition to ceria
Hamada, Shota, Uegaki, Shinya, Tanabe, Hidetaka, Nakayama, Tomohito, Jinjo, Itsuki, Kurono, Seita, Oishi, Shunsuke, Narita, Keiichi, Onishi, Tetsuro, Yasuda, Kazuya, Matsumura, Daiju, Tanaka, Hirohisa
Technical Paper
Exploring Compatibility Limits for Lubricating Greases Formulations.2025-01-8469To be published on 04/01/2025
Grease compatibility is thought to be an important consideration for both grease manufacturers and end-users. When switching from one grease to another, the supplier is typically asked if the two greases are compatible. Two incompatible greases could be detrimental to the equipment and even cause failure in extreme cases. However, provided due care is taken, switching from one grease to another is quite possible. Grease incompatibility is a multicomplex issue that can occur due to interactions between the thickeners, the base oils or the additives. Almost 70% of the global grease demand is based on lithium thickener chemistry. Due to the increasing debate on the gradual decrease on lithium greases reliance, the interchangeability between other types of thickeners is becoming more and more relevant. The aim of this study is to investigate the compatibility of various commercially available grease formulations that could replace lithium-based greases – namely aluminum complex, polyurea
Dodos, George S., Kaframani, Nora
Technical Paper
Spray Characterization in a Constant Volume Chamber of Aluminum Oxide Nanoparticles-Diesel Blends2025-01-8455To be published on 04/01/2025
Aluminum oxide (Al₂O₃) nanoparticle 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
Technical Paper
Innovative Methods for Predicting Material Stress-Strain Curves Based on Transfer Learning and Artificial Intelligence2025-01-8317To be published on 04/01/2025
The mechanical properties of materials play a crucial role in predicting performance across various applications. However, traditional methods for measuring these properties often involve complex, resource-intensive, and time-consuming tests, which may be impractical in certain situations. The Small Punch Test (SPT) is a small-sample detection technique for evaluating material mechanical properties, characterized by its "non-destructive" nature: applying localized loads to small specimen samples and measuring the resulting deformation. While SPT can obtain load-displacement curves for specimens, it cannot directly reflect material mechanical properties and relies on empirical formulas for estimation. To address this challenge, we designed a specialized SPT experiment and fixture, and established a Finite Element Method (FEM) model. We developed a multi-fidelity model capable of predicting the mechanical properties of steel and aluminum alloys, representing a novel machine learning
Zou, Jie, Chen, Yechao, Li, Shanshan, Huayang, Xiang
Technical Paper
Fatigue strength of grey cast iron – new insights regarding the size effects2025-01-8238To be published on 04/01/2025
Grey 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 the good characteristics in relation to lubrication, heat conductivity and damping. Especially engine parts 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. Within a comprehensive study, different GJL materials have been investigated at Fraunhofer LBF to provide a more detailed information about the influence of size effects on its fatigue strength. Accordingly, a variety of specimen sizes, geometries, and microstructures were
Bleicher, Christoph, Kansy, Axel
Technical Paper
A Modified Johnson-Cook Model Considering Strain-Temperature Coupling for Welding Simulation of Aluminum Alloy Bumper2025-01-8243To be published on 04/01/2025
The metal inert-gas (MIG) welding technique employed for aluminum alloy automotive bumpers involves 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 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
Technical Paper
A review of warm forming for steels: History, Methodology and Emerging trends2025-01-8814To be published on 04/01/2025
Many manufacturing techniques and process modifications have been implemented over the years to improve the formability of sheet metals. Warm forming of sheet metals is one such established method. However, it is more commonly and successfully applied to aluminum grades. The reevaluation of less-used metal forming technologies, such as warm forming and sheet hydroforming for steel, is a response to the challenges posed by competitive processes like large castings and the geometry requirements of new BEV parts. By understanding the effects of elevated temperatures (below recrystallization temperatures) on different steel grades and the impact of various heating methodologies, the industry can adapt and optimize these proven techniques for modern applications. This paper is a comprehensive summary of the effect of elevated temperatures on various grades of steel. Different heating techniques, their cycle times and effects on final forming feasibility is contrasted. The effect of
Kella, Caroline, Wormald, Tom
Technical Paper
Deformation Behavior and Springback Analysis of Anti-Collision Beam on Bending Forming2025-01-8247To be published on 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 anti-collision 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
Zhang, Shizhen, Meng, Dejian, Gao, Yunkai
Technical Paper
Image-based Machine Learning Methods in Materials Microstructure and Failure Analysis2025-01-8324To be published on 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
Technical Paper
Design and Optimization of a Novel Aluminum-Intensive Spaceframe-Based Electric Mailvan Prototype Driven by CAE2025-01-8323To be published on 04/01/2025
Despite the known advantages of aluminum in terms of its lower density and comparable strength-to-weight as well as stiffness-to-weight ratios as those of steel, superior recyclability and high residual value, etc., there are only a handful of vehicles in global markets, mostly outside the reach of the common man, made primarily of aluminum. As cost of material and joining of parts is a deterrent in large scale adoption of aluminum as a material of choice for vehicle body design, a novel architecture is necessary for minimizing weight, maximizing performance and lowering cost of tooling. Additionally, a lightweight vehicle cannot be behind in terms of crash safety compared to its predominantly steel body-based counterparts. With these objectives in mind, a novel aluminum-intensive electric mailvan based on a spaceframe body architecture comprised mainly of low-cost extrusions has been designed and prototyped primarily driven by CAE. The design methodology consists of selective testing
Tanaya, Sushree, Deb, Anindya
Technical Paper
3D Design and Analyses of an IC Engine Piston under fatigue Test Conditions using CNTs for the Next-Generation of Motorcycles2025-01-8359To be published on 04/01/2025
CNTs play an important role in engineering applications, especially in engine pistons design for the next-generation of motorcycles. This work presents a comprehensive analyses 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 simulation results
Ali, Salah H. R., Ahmed, Youssef G. A., Ali, Amr S.H.R.
Technical Paper
Evaluation of additively manufactured thermoplastic composite magnetic field shielding for stepper motors2025-01-8201To be published on 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.
Technical Paper
A Methodology to Characterize the Influence of Paint Baking and Pre-Straining on the Tensile Properties and Sheared Edge Sensitivity of Third Generation Advanced High Strength Steels2025-01-8223To be published on 04/01/2025
The existing ASTM A653 standard for characterization of the bake hardening index (BHI) involves application of a pre-strain followed by bake hardening and subsequent testing of an ASTM-E8 tensile coupon that can lead to premature fracture in steels with high strengths and lower elongations. To this end, a new test procedure is proposed with application to 980 and 1180 MPa third generation advanced high strength steels (3G-AHSS). The proposed methodology involves pre-straining over-sized tensile specimens using the so-called KS-1B geometry, which is followed by the extraction of an ASTM E8 sample from the gauge region on which the baking and secondary tensile testing are conducted. Various pre-strain levels from 2% to 10% were considered with all tests performed using the proposed methodology avoiding premature fracture compared to the ASTM A653 method that was evaluated for pre-strain levels of 2% and 8%. Finally, to characterize the influence of paint baking on regions with
Northcote, Rhys, Berry, Avalon, Narayanan, Advaith, Tolton, Cameron, Lee, Haea, Smith, Jonathan, McCarty, Eric, Butcher, Cliff
Technical Paper
European Initiatives addressing High efficiency and low cost electric motors for circularity and low use of rare resources2025-01-8806To be published on 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, CO2 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 SRIA . The E
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
Technical Paper
Thermomechanical Fatigue Behavior of Gray Cast Iron2025-01-8319To be published on 04/01/2025
Gray cast iron is a cost-effective engineering material widely used for heavy duty engine blocks and brake rotors of vehicles. Thermomechanical fatigue condition is easily achieved in vehicle operation due to the temperature fluctuation in the components in assembly condition. To speed up the design of the component, it is critical to investigate the thermomechanical fatigue (TMF) behavior of the gray cast iron. In the present study, a series of fatigue tests including isothermal low cycle fatigue (LCF) test at elevated temperatures up to 700°C, in-phase (IP) and out-of-phase (OP) TMF tests in different temperature ranges have been conducted. 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 aspects to be captured in virtualization.
Liu, Yi, Lee, Heewook, Hess, Devin, Coryell, Jason
Technical Paper
Fundamental science on oxygen storage capacity of cerium complex oxides for advanced on-board diagnostics (1) Kinetic observation of cerium valence change using synchrotron radiation2025-01-8474To be published on 04/01/2025
For internal combustion engine vehicles, the deterioration of emissions, unlike fuel consumption and power output, cannot be perceived by the driver. For over 30 years, SAE has played a leadership role in ground vehicle emissions reduction and on-board diagnostics (OBDs). OBD in gasoline vehicles is detected by measuring the fluctuations in the rear oxygen sensor due to the degradation over time of the oxygen storage capacity (OSC) of cerium complex oxides (ceria) contained in automotive catalysts. Both the amount and rate of OSC in ceria are affected by the composition including dopants and precious metals supported on the surface, and many studies have been reported [1-3]. With more precise detection limits for OBD being required, a deeper understanding of ceria's OSC has become essential. In this study, we took advantage of the high energy of the synchrotron radiation in SPring-8 to perform an operando analysis using time-resolved dispersive X-ray absorption fine structure (DXAFS
Tanaka, Hirohisa, Matsumura, Daiju, Uegaki, Shinya, Hamada, Shota, Aotani, Takuro, Kamezawa, Saeka, Nakamoto, Masami, Asai, Shingo, Mizuno, Tomohisa, Takamura, Riku, Goto, Takashi
Technical Paper
Material-Combined Vehicle Brake Disc Design for Enhanced Cooling Performance2025-01-8189To be published on 04/01/2025
The improvement of heat dissipation performance of ventilated brake discs is vital of braking safety. The usual 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 have better thermal conductivity so that a more uniform temperature gradient distribution shall be formed; C-SiC have poorer heat capacity yet better thermal stability; 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 disc using different friction materials and geometry structures. At the level of material application, Al-MMC and C-SiC friction layer are compared. At the level
Wang, Jiarui, Jia, Qing, Zhao, Wentao, Xia, Chao, Yang, Zhigang
Technical Paper
Application of 1.7GPa Martensitic Steel in Dash Lower Cross Member to Enhance Automotive Frontal Impact Safety2025-01-8218To be published on 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
Technical Paper
Mitigating Paint Blistering Defects in Aluminum Casted Parts: A QC Story Approach Utilizing Computed Tomography2025-01-8229To be published on 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 Aluminium 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
Technical Paper
Liquid Viscosity Decoupling Measurement Based on U-Shaped Tungsten Wire Sensor2025-01-8460To be published on 04/01/2025
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
Technical Paper
Establishment of Failure Simulation Models for Bonding of Carbon Fiber Laminated Skins and Cores in Monocoque Structures Based on Formula Student Racing Cars2025-01-8006To be published on 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. Traditional truss steel tube body have drawbacks such as low strength and high weight, which has led 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 of carbon fiber laminates, the outer skin is primarily subjected to tensile forces. This results in significant stress at the adhesive layer between the skin and the core material at both ends of the laminate, leading 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
Ning, Zicheng
Technical Paper
In-situ Nanoindentation and Finite Element Analysis for Evaluating the Young’s Modulus of Anode Current Collectors in Lithium-ion Batteries2025-01-8133To be published on 04/01/2025
As the use 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 metal collector exerts a significant impact on the tensile properties of the electrode and also on the internal fracture of the cell. Tensile tests are unable to obtain the mechanical properties of the collector in situ, and the stripping process tends to cause additional damage to the collector. Therefore, nanoindentation tests are required to gain the mechanical properties of the collector. Nanoindentation testing represents the primary methodology for the determination of the mechanical properties of thin films. Commercial indentation instruments typically employ the Oliver-Pharr method for the assessment of material mechanical properties. However, this method is subject to limitations due to the constraints imposed by sample boundary conditions. In order to obtain an accurate measurement of the elastic
Dai, Rui, Sun, Zhiwei, Park, Jeongjin, Xia, Yong, Zhou, Qing
Technical Paper
Materials Innovation in Thermal Management: Advancing Aluminum Alloy Technologies for the Next-Generation Electrical Vehicle Battery Cold Plate2025-01-8162To be published on 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 global heat exchanger market trends from a materials perspective, focusing on the evolution of alloy mechanical, fatigue, and thermal properties. Specifically, we investigated the transition from traditional
Jalili, Mehdi, Wang, Xu, Razm-poosh, Hadi
Technical Paper
A DEM-FEM Coupled Analysis of Ultrasonic Shot Peening Dynamics and Surface Modification Parameters in Aluminum Alloys2025-01-8239To be published on 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
Technical Paper
Advanced Characterization of Mechanical and Cyclic Fatigue Properties of Aluminum Cast Materials for Optimized Industrial Applications2025-01-8237To be published on 04/01/2025
Given the strategic importance of aluminum cast materials in producing lightweight, high-performance products across industries, it is funda-mental to assess their mechanical and cyclic fatigue properties thor-oughly. This investigation is primarily for optimizing material utiliza-tion 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 sub-jected to different heat
Qaralleh, Ahmad, Niewiadomski, Jan, Bleicher, Christoph
Technical Paper
Parameter calibration method of Johnson-Cook constitutive model based on tensile and compression tests2025-01-8242To be published on 04/01/2025
In new energy vehicles, aluminum alloy has become increasingly prevalent due to 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. However, obtaining precise material parameters for accurate predictive simulations remains a challenge. The Johnson-Cook model is widely utilized in the automotive industry for impact and molding applications due to its strong applicability and simple form. Nevertheless, variations in material composition, processing techniques, and manufacturing methods of aluminum alloy can lead to differences in material properties. Furthermore, components are constantly subjected to a complex stress state during actual service. The conventional parameter calibration method only relies on specimens from quasi-static and dynamic tensile tests, which has numerous limitations. To address this issue, this paper proposes an
Kong, Deyu, Gao, Yunkai
Technical Paper
Understanding Forming Characteristics of 980 MPa and 1180 MPa strength level AHSS with various Microstructures2025-01-8222To be published on 04/01/2025
For electrical vehicle (EV) automotive body-in-white (BIW) structures, protection of passengers and battery in crash event becomes critically important. In addition to energy absorption, intrusion protection for battery and vehicle becomes extremely important and Advanced high strength steels (AHSS), like dual phase (DP)/multi-phase (MP)/complex phase (CP)/retained austenite bearing (GEN3) steels and Press hardened steels (PHS), have become material of choice for design for these components. Higher yield strength materials especially in 980/1180MPa MP and CP category are chosen for part design over conventional low yield strength DP to meet crash and performance targets. In this study, the forming characteristics including both global and local formability are evaluated and compared among 980 DP/MP/CP grades. Formability tests, such as forming limit curve (FLC), true fraction strain, V bend, half dome, and hole expansion tests are conducted. Microstructure analysis to understand the
Shih, Hua-Chu, Pednekar, Vasant, Shi, Ming, Singh, Jatinder, Tedesco, Sarah, Wu, Wei
Technical Paper
Material Characterization of the Newly Developed Advanced High Strength Steels for Prediction of Crash Performance2025-01-8220To be published on 04/01/2025
New highly ductile AHSS steel grades with tensile strength greater than 980 MPa have been developed with the aim of combining high strength and excellent formability. The new jetQ[TM]-Family offers high local and global ductility which is expected to contribute to the improvement of vehicle crash performance. For reliable design and management of vehicle crash performance, material modeling including work hardening behavior, strain rate dependence 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 both the 980jetQ[TM] and conventional Dual-Phase (DP) are investigated through simple tensile and V-bending fracture tests incorporating experiment-numerical hybrid ductile fracture analysis. Based on the experimental results, the material parameters in Hosford-Coulomb fracture model are determined for the numerical
Sato, Kentaro, Sakaidani, Tomohiro, Ohnishi, Yoichiro, Paton, Adrian, Roesen, Hartwig
Technical Paper
Elevated Fracture Resistance of Q&P1180 after Forming and Paint-Baking Treatment2025-01-8221To be published on 04/01/2025
According to precedent studies, many automotive advanced high-strength steel (AHSS) grades obtain reinforced strength yet maintain fracture resistance after forming and paint-baking treatment. Concisely, the mechanism of such behavior is that the Cottrell Atmospheres can only impede the mobile dislocations during the early stage of the plastic deformation and cannot last durable enough to affect the fracture. Nevertheless, a distinctive AHSS grade, Q&P1180, was reported in this work that it obtained some elevated fracture resistance as well as strength after forming and baking. Such a uniqueness was speculated to be caused by 1) no soft ferrite in the microstructure and 2) the transformed fresh martensite being tempered and softened by the paint-baking cycle. To prove this speculation, a series of mechanical experiments were conducted, covering stress-state, strain-rate, and temperature dependencies. Eventually, the test results characterized the elevated fracture resistance of Q&P1180
Hu, Jun, Sun, Yeting, Thomas, Grant
Technical Paper
Microstructure, Tensile and Fracture Behaviors of Squeeze Cast Wrought Mg Alloy AZ802025-01-8230To be published on 04/01/2025
Wrought magnesium alloy AZ80 with a thick section of 20 mm was prepared by squeeze casting (SC) and permanent steel mold casting (PSMC). The porosity measurements of the SC and PSMC showed that the SC AZ80 had a porosity of 0.52%, which was the 77% lower than that (2.21%) of the PSMC counterpart. The microstructure analyses and phase identification indicated that the cast AZ80 alloy consisted of a primary α-Mg phase, eutectic Mg-Al-Zn phases and Al-Mn intermetallic. The fine primary α-Mg dendrites and a high amount of the intermetallic phase were present in the SC AZ80 alloy. The yield strength (YS), ultimate yield strength (UTS), elongation (ef), elastic modulus (E) and strain hardening rate of the cast AZ80 specimens were evaluated by tensile testing. The measured engineering stress versus strain curves showed that the SC AZ80 alloy exhibited 84.68 MPa in YS, 168.23 MPa in UTS, 5.07% in ef, and 25.1GPa in modulus while the YS, UTS and ef of the PSMC specimen were only 71.61 MPa
Ying, Peilin, Hu, Henry, Hu, Anita, Shen, Wutian
Technical Paper
Zero circumferential material flow line-based method for reducing stamping simulation cost2025-01-8224To be published on 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
Technical Paper
Predicting Forming Limit of Hot Stamping Boron Steel using a Modified Zener-Hollomon Parameter based Ductile Failure Criterion2025-01-8225To be published on 04/01/2025
This study combines a recently proposed ductile failure criterion with a modified Zener-Hollomon parameter to predict the forming limit of a boron steel at hot stamping temperatures. The Zener-Hollomon parameter is modified to include a parameter that accounts for the non-linear variation of strain rate during hot stamping. The combined ductile failure criterion takes into account the critical damage at localized necking or at fracture as a function of strain path, initial sheet thickness and strain rate variation. The process of determining various parameters in the failure criterion is explained. The capability of the ductile failure criterion is demonstrated by predicting forming limit of a boron steel in an isothermal Nakajima dome test. The criterion is further demonstrated by predicting fracture in hot stamping a B-Pillar part (NUMISHEET Benchmark #3 2008).
Sheng, ZiQiang, Mallick, Pankaj
Technical Paper
Self-Piercing Riveting (SPR) of magnesium high pressure die casting and dissimilar materials2025-01-8231To be published on 04/01/2025
Solid state joining processes are attractive for magnesium alloys as they can offer robust joints without the porosity issue usually 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. While SPR has been proven effective for joining aluminum and steel, it has yet to be successfully adapted for magnesium alloys. 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 employment of new equipment or introduction of extra processing steps. The aim of this work is to introduce a SPR technique which adapts current SPR machines with minimal
Tabatabaei, Yousef, Wang, Gerry, Weiler, Jonathan
Technical Paper
Stir Casting Synthesis and Evaluation of SiC Nanoparticle-Reinforced AZ31 Magnesium Alloy Nanocomposites2025-01-5013To be published on 03/10/2025
In an attempt to improve its mechanical characteristics in the as-fasted conditions, the AZ31 Mg alloy was investigated herein from being reinforced with diverse SiC weight percentages (3, 6, and 9 wt.%). To develop lightweight AZ31-SiC composites, a simple and inexpensive technique, the stir casting process, was used. Microstructural analysis of the as-cast samples showed that the SiC particles were distributed rather uniformly, were firmly bonded to the matrix, and had very little porosity. The substantial improvement in tensile, compressive, and hardness characteristics was caused by fragmentation and spreading of the Mg17Al12 phase, while the addition of SiC had only a slight effect on the microstructure in the as-cast state. Surfaces of AZ31-SiC composites were analyzed using scanning electron microscopy. A study identified the AZ31-SiC composite as a unique material for applications involving a high compressive strength, such as those found in the aviation and automobile
Thillikkani, S., Kumar, N. Mathan, Francis Luther King, M., Soundararajan, R., Kannan, S.
Technical Paper
Steel, Corrosion-Resistant, Bars, Wire, Forgings, Mechanical Tubing, and Rings 16Cr - 4.0Ni - 0.30Cb - 4.0Cu Consumable Electrode Remelted Solution Heat Treated, Precipitation Hardened (H925)AMS5622/H925 (Current)02/25/2025
This specification covers a corrosion-resistant steel product 8 inches (203 mm) and under in nominal diameter, thickness, or for hexagons least distance between parallel sides in the solution and precipitation heat-treated (H925) condition.
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Steel, Corrosion-Resistant, Bars, Wire, Forgings, Mechanical Tubing, and Rings 16Cr - 4.0Ni - 0.30Cb - 4.0Cu Consumable Electrode Remelted Solution Heat Treated, Precipitation Hardened (H900)AMS5622/H900 (Current)02/25/2025
This specification covers a corrosion-resistant steel product 8 inches (203 mm) and under in nominal diameter, thickness, or for hexagons least distance between parallel sides in the solution and precipitation heat-treated (H900) condition.
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Nut, Self-Locking, Nickel Alloy, UNS N07001, 1400 °F, 180000 psi, UNJ Thread Procurement SpecificationAS5878B (Current)02/25/2025
This specification establishes the requirements for the following types of self-locking nuts in thread diameter sizes 0.1380 through 0.6250 inch: a Wrenching Nuts: i.e., hexagon, double hexagon, and spline nuts. b Anchor Nuts: i.e., plate nuts, gang channel nuts, and shank nuts. The wrenching nuts, shank nuts, and nut elements of plate and gang channel nuts are made of a corrosion- and heat-resistant nickel-base alloy of the type identified under the Unified Numbering System as UNS N07001 and of 180000 psi axial tensile strength at room temperature, with maximum conditioning of parts at 1400 °F prior to room temperature testing.
E-25 General Standards for Aerospace and Propulsion Systems
Technical Standard
Tolerances Nickel, Nickel Alloy, and Cobalt Alloy Bars, Rods, and WireAMS2261M (Current)02/25/2025
This specification covers established manufacturing tolerances applicable to bars, rods, and wire of nickel, nickel alloy, and cobalt alloys ordered to inch-pound dimensions. These tolerances apply to all conditions, unless otherwise noted. The term “excl” is used to apply only to the higher figure of a specified range.
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, CROSSLINKED MODIFIED ETFE, LOW FLUORIDE, NORMAL WEIGHT, SILVER-COATED COPPER, 200 °C, 600 VOLT, ROHSAS22759/54C (Current)02/25/2025
AE-8D Wire and Cable Committee
Technical Standard
Steel, Corrosion-Resistant, Bars, Wire, Forgings, Mechanical Tubing, and Rings 16Cr - 4.0Ni - 0.30Cb - 4.0Cu Consumable Electrode Remelted Solution Heat Treated, Precipitation Hardened (H1075)AMS5622/H1075 (Current)02/25/2025
This specification covers a corrosion-resistant steel product 8 inches (203 mm) and under in nominal diameter, thickness, or for hexagons least distance between parallel sides in the solution and precipitation heat-treated (H1075) condition.
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Aluminum Alloy, Seamless Drawn Tubing, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061-T6), Solution and Precipitation Heat TreatedAMS4082S (Current)02/25/2025
This specification covers an aluminum alloy in the form of seamless drawn tubing with wall thickness of 0.025 to 0.500 inch (0.64 to 12.70 mm), inclusive (see 8.5).
AMS D Nonferrous Alloys Committee
Material Specification
Aluminum Alloy, Sheet and Plate, Alclad 4.4Cu - 1.5Mg - 0.60Mn (2024-O with 1-1/2% Alclad) AnnealedAMS4040R (Current)02/25/2025
This specification covers an aluminum alloy in the form of sheet and plate, alclad two sides, 0.188 to 1.000 inch (4.775 to 25.400 mm), inclusive, in thickness, supplied in the annealed (O) condition (see 8.5).
AMS D Nonferrous Alloys Committee
Material Specification
Aluminum Alloy Tubing, Seamless, Drawn, 4.4Cu - 1.5Mg - 0.60Mn (2024-O), AnnealedAMS4087K (Current)02/25/2025
This specification covers an aluminum alloy in the form of seamless drawn tubing having nominal wall thickness of 0.018 to 0.500 inch (0.46 to 12.70 mm), inclusive (see 8.4).
AMS D Nonferrous Alloys Committee
Material Specification
Aluminum Alloy, Hand Forgings and Rolled Rings, 6.3Cu - 0.30Mn - 0.18Zr - 0.10V - 0.06Ti (2219-T852/T851), Solution Heat Treated, Mechanically Stress Relieved, and Precipitation Heat TreatedAMS4144H (Current)02/25/2025
This specification covers an aluminum alloy in the form of hand forgings 17 inches (432 mm) and under in nominal thickness and rolled rings up to 6 inches (152 mm), inclusive, in nominal thickness at the time of heat treatment (see 8.6).
AMS D Nonferrous Alloys Committee
Material Specification
Nickel-Iron Alloy, Corrosion- and Heat-Resistant, Welding Wire, Consumable Electrode Remelted or Vacuum Induction Melted, 12.5Cr - 42.5Ni - 6.0Mo - 2.7Ti - 0.015B - 35Fe (Alloy 901)AMS5830D (Current)02/25/2025
This specification covers a corrosion- and heat-resistant nickel-iron alloy in the form of welding wire.
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Items per page:
1 – 50 of 33767