Browse Topic: Metals

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Advancing Sustainable Electric Vehicles: A Simulation-Driven Study on Rare Earth-Free Motors and Battery Technologies2026-01-0242To be published on 04/07/2026
As electric vehicles (EVs) become more popular, the growing dependence on rare earth materials in their motors and batteries has raised concerns about supply risks, environmental impact, and rising costs. Finding alternatives to these materials is essential to making EVs more sustainable and affordable for everyone. This study aims to explore new motor designs and battery chemistries that reduce or eliminate the use of rare earth elements. We will focus on promising options like induction and wound rotor motors, as well as ferrite and iron-nitride magnets that can replace traditional rare earth magnets in EVs. On the battery side, we will look at lithium-iron-phosphate (LFP) and sodium-ion batteries, which offer a safer and more cost-effective alternative while maintaining good performance. A big part of this work involves using advanced simulations to predict how these new materials and designs will perform. This lets us optimize the components before building physical prototypes
Saraswat, Shubham, Vishe, Prashant
Investigation on Microstructure and Mechanical Properties in the Dissimilar Joining of WE43 to AA7075 Alloy using FSW2026-01-0229To be published on 04/07/2026
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 refinement of grain 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
Ahmad, Tariq, Khan, Noor Zaman, Ahmad, Babar, Siddiquee, Arshad Noor
Investigation into Dynamic Behavior of Jute-Glass-Aluminium Hybrid Polymer Composites for Automotive Applications2026-01-0245To be published on 04/07/2026
The research work in this paper investigates the development and dynamic characterization of lightweight hybrid polymer composites tailored for automotive applications. Fiber-reinforced polymer composites, owing to their high specific strength and stiffness, have emerged as promising candidates to replace conventional materials. Expanding on the current trend of hybridization that blends natural and synthetic fibers to optimize mechanical strength and vibration-damping behavior, this study incorporates aluminum perforated sheets (Al) as additional reinforcement to increase stiffness without significantly increasing weight. Jute (J) fibers, known for their inherent damping capability, were combined with glass fibers (G) and Al sheets. Six symmetric hybrid laminates G/J/Al/J/G, J/G/Al/G/J, J/J/Al/J/J, G/G/G/Al/G/G/G, and J/J/J/J/J were fabricated using hand lay-up followed by compression molding. The modal frequencies and damping properties were obtained through experimental testing
Salve, Aniket, Mache, Ashok, Nalawade, Dattatraya, Joshi, Shardul
Impact of C-rates on Electrical Behavior of Li-ion Batteries under Coupled Temperature-load Conditions2026-01-0383To be published on 04/07/2026
The utilization of lithium-ion batteries in electric vehicles becomes increasingly common. Battery performance degradation is influenced by both temperature and boundary constraints. Monitoring the usable cell capacity (UCC) under real-world operating conditions is essential for ensuring accurate state-of-health estimation. 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 charge/discharge rates frequently results in deviations between laboratory characterization and on-board BMS capacity estimation. To investigate the impact of C-rates under coupled temperature-load conditions, we conducted long-term cycling tests on LFP/graphite pouch cells at 25 °C and 45 °C under different constrained conditions. The UCC was evaluated at different test rates (1/20C, 1/3C, and 1C) as an indicator of aging. The results show that
ZHANG, Shan, Niu, Zhice, Xia, Yong
High Strain-Rate Behaviors of Fiber Reinforced Composites in Principal and Off-Axis Directions2026-01-0175To be published on 04/07/2026
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 orthotropic glass, carbon and a natural
Bawa, Prashant, Deb, Anindya, Zhu, Feng
Design and Simulation Analysis of an Integrated Honeycomb-filled Front Bumper for a Special Vehicle2026-01-0475To be published on 04/07/2026
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-impact beam structure based on aluminum alloy additive manufacturing technology. A novel bumper structure is proposed, which integrates the front bumper and the front impact 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 impact beam of traditional passenger vehicles, an integrated design of the vehicle front bumper-impact beam structure is carried out and
王, Xufan, Yuan, Liu-kai, Zhang, tangyun, Wang, Tao, Zhang, Ming, Wang, Liangmo
Multi-material topology optimization using difference-based equivalent static load method2026-01-0173To be published on 04/07/2026
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
Efficient casting system design through simulation for AlCoCrFeNi high-entropy alloy2026-01-0176To be published on 04/07/2026
This study depicts the design, simulation, and fabrication of an equiatomic Al–Co–Cr–Fe–Ni high entropy alloy (HEA) through casting using Siemens NX CAD and ADSTEFAN simulation software. The part and gating system, including the sprue, runner, pouring cup, and riser, were modeled to generate the STL file and optimization was done through iterative simulation. Fluid flow and solidification analyses were performed to simulate the filling temperature, cold shut, and soundness of the casting. The optimized gating design is expected to provide uniformity in the temperature distribution, avoid defects during solidification and to eliminate shrinkage cavities in the cast alloy. HEA was fabricated by utilizing the validated gating system using vacuum induction melting of high-purity elemental granules. Further microstructural investigation using methods like SEM and EDS showed a uniformity of Al, Co, Cr, Fe, and Ni in near-equiatomic proportions. The optimization of riser-fed design
Vashistha, Saurabh, Rawat PhD, Pankaj, singh PhD, Shailesh, Pathak, Sunil
A study on Crack propagation characteristics of interlaced holes for key automotive components.2026-01-0186To be published on 04/07/2026
Aiming at the engineering problem that the stress interference of interlaced holes dominates crack propagation and directly affects driving safety in the hole group structure of key components such as chassis and body frame in the automotive field, in order to accurately reveal the quantitative influence of key parameters of interlaced hole placement (crack deflection Angle, longitudinal hole spacing) on the crack evolution of automotive hole group components, This study adopts the approach of numerical simulation combined with variable control to conduct systematic analysis. Taking an aluminum alloy thin plate with two relatively initial cracks (a commonly used structural material for automobiles) as the research object, multiple sets of typical interlocking hole structure variable models of automotive components covering different crack deflection angles and longitudinal hole spacings were constructed in the ABAQUS software. The J-integral was calculated by the circumscribed line
Chen, Yechao, Zhan, Zhenfei, Tang, Weiqin, Yang, Yutong, Gan, Yuan, Yan, Kaibo, HUANG, Shiyao
Optimizing joint efficiency in stainless steel-aluminum alloy FSW joints through advanced parameter control2026-01-0228To be published on 04/07/2026
The present work investigates the friction stir welding (FSW) of dissimilar materials, specifically stainless steel 304 and aluminum alloy AA2024-T3, to analyze their tensile strength behavior. The significant challenges inherent in joining these materials, stemming from their vastly divergent thermal and mechanical properties, are addressed through a structured experimental and statistical methodology. The L18 Taguchi mixed orthogonal array was employed to systematically evaluate the influence of three critical process parameters: tool rotational speed, welding speed, and tool pin offset. Eighteen experimental trials were conducted using a butt joint configuration. The analysis identified tool rotational speed as the most influential parameter affecting the joint integrity. A combination of 450 rpm rotational speed, 20 mm/min welding speed, and a 1.5 mm pin offset toward the aluminum side yielded the optimum results, achieving a peak ultimate tensile strength (UTS) of 344.7 MPa and a
Mir, Fayaz Ahmad, Khan, Noor Zaman, Pali, Harveer Singh
Predicting Tensile Properties of Cast Stainless Steels via Machine Learning2026-01-0237To be published on 04/07/2026
In the category of cast stainless steels, there are several variants per different level of addition of chromium (Cr), vanadium (V) along with some minor elements, such as molybdenum (Mo), niobium (Nb), tungsten (W) 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 (ML), the effects of each element on the tensile properties of the cast stainless steel are studied. The ML 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
Wear and Friction of PTFE and PEEK Coated Cast Iron for Piston Ring Application2026-01-0240To be published on 04/07/2026
In engine 30% of the total energy is lost due to the friction between piston ring and cylinder liner due to their constant rubbing motion. A piston that reciprocates at high speeds has piston rings that constantly scrape against the wall leading to high frictional losses within the engine. The engine has to work against this resistance to provide the required power, and hence it will consume more fuel. For this reason, material used for these components is more crucial. Reduction of surface friction between moving parts in order to increase overall efficiency can be achieved by suitable coating. The most commonly used piston rings are coated with chromium layers that are electroplated which is being replaced by chrome plating. Low coefficient of friction (COF) and high wear resistance can be achieved by self-lubricating coating of PTFE and PEEK polymer-based composite coatings. Experimental results showed that the PEEK and PTFE coating performed better in terms of friction and wear
Rajendran, R., Tamilarasan, T R, J, Chandradass
Role of Advanced Polishing Techniques in Enhancing Al–Cu Diffusion Bonding: Eliminating Impurities and Voids for High-Performance Conductive Joints2026-01-0235To be published on 04/07/2026
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. In this work, we introduce a novel integration of electropolishing pretreatment with ultra-thin copper foil (<50 µm) assisted diffusion bonding to achieve cleaner, void-free interfaces. Electropolishing effectively removes surface contaminants and oxides, enabling intimate atomic contact during bonding and minimizing the formation of brittle intermetallic phases. A systematic investigation of bonding parameters temperature, pressure, and time was conducted using a custom-designed graphite clamping system. Microstructural analyses reveal that polishing plays a pivotal role in producing uniform, impurity-free interfaces, resulting in reduced intermetallic thickness
Abbasi, Hossein, Liu, Yi, Su, Jinrong, WANG, Andy, xiao, Yaohong, Wang, Qigui, CHEN, LEI
Comparison of Formability Performance Between CR550LA and CR590DP2026-01-0178To be published on 04/07/2026
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 CR340LA, CR420LA, and CR550LA are evaluated in overall formability and in-use performance when compared to CR590 dual phase (DP) grade. The evaluations
Shih, Hua-Chu, Brown, Lindsay, Pednekar, Vasant, Shi, Ming, Tedesco, Sarah
A Data-Driven Model for Predicting Casting Solidification Time and Mold Thermal Stress2026-01-0233To be published on 04/07/2026
This study proposes a data-driven surrogate modeling framework for predicting solidification time and mold thermal stress during low-pressure die casting (LPDC) of aluminum alloy wheels. The methodology employed an optimal Latin hypercube design (OLHD) to sample key parameters including cooling channel geometry and process conditions. A sequential simulation methodology combining ProCAST and Abaqus was implemented to generate a comprehensive dataset of solidification times and thermal stress distributions. Based on this dataset, surrogate models were developed using Support Vector Regression, Kriging, and Polynomial Response Surface Methodology, with their hyperparameters automatically tuned through Bayesian Optimization (BO). The optimized models were rigorously evaluated using four statistical metrics: Coefficient of Determination (R²), Mean Squared Error (MSE), Mean Absolute Error (MAE), and Root Mean Squared Error (RMSE). The evaluation results show that the BO-SVR model
fuhao, Fan, Zhan, yunlang, Zhan, Zhenfei, Yang, Yutong, Xiao, yong, HUANG, SHIYAO
Effective Prediction of the Mechanical Properties of Glue-Laminated Motor Core with consideration of glue disposition and stacking factor.2026-01-0177To be published on 04/07/2026
This study presents a practical approach for predicting the mechanical properties of glue-laminated motor cores, with a particular focus on the influence of glue disposition patterns and coverage rate, to enable more accurate material modeling and reliable NVH and other general structural analysis. Since glue bonding and lamination stacking are essential for ensuring the structural integrity of motor stator cores, variations in glue implementation introduce significant changes in both in-plane and out-of-plane stiffness properties. To address this, a homogenization framework based on the unit-cell method, considering detailed glue application information, is employed. The laminated structure is idealized as an orthotropic material, and the variation of in-plane properties in different directions is considered. Unlike simplified coverage-rate models, the proposed method incorporates localized glue distribution patterns—such as teeth, core back iron, and edge-concentrated regions like
Nie, Zifeng
Tensile and Fatigue Behavior of High Pressure Die Cast AE44 Magnesium Alloy at Elevated Temperatures2026-01-0234To be published on 04/07/2026
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 deformation at the temperature below 150°C. With increasing temperature, the anelasticity disappears, and tensile and cyclic behaviors become similar to 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 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
Lightweight Bubble Sheet Panel To Reduce Inverter Noise and Vibration for Electric Vehicles2026-01-0442To be published on 04/07/2026
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, due to its large radiative panel, becomes a dominant noise source. 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 results in excessive mass, cost, and packaging challenges. A new, patented bubble sheet panel design has been developed to enhance the structural strength and damping of the inverter while significantly reducing its mass. A thin sheet of aluminum or magnesium 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
He, Song, Bobel, Andrew, Naismith, Gregory, Yi, Wenwen, Patruni, Pavan Kumar
A Study on Fatigue Life Prediction Method for Point-Based Joints Considering Multiple Fracture Modes – FDS, Blind Rivet, and Blind Nut Focus2026-01-0180To be published on 04/07/2026
The application of light weight alloys for vehicle bodies such as aluminum alloys and composite materials are rapidly advancing to support the construction of multi-material vehicle bodies. 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 introduces new challenges in manufacturing, particularly in joining technologies. Since different materials have varying mechanical properties, thermal behaviors, and surface characteristics, selecting appropriate joining methods is essential to ensure structural integrity and durability. Depending on the material types, thicknesses, production processes, and cost constraints, various joining techniques—such as
Takuno, Sougo, Isono, Toshiyuki, Urakawa, Kazushi, Goto, Suguru, Kawamura, Hiroaki, Niisato, Eita, Ishigami, Yuta
Modelling and Analysis of Complex Shaped Cracks2026-28-0048To be published on 02/12/2026
This study provides an extensive analysis through finite element analysis (FEA) on the effects of fatigue crack growth in three different materials: Structural steel, Titanium alloy (Ti Grade 2), and printed circuit board (PCB) laminates based on epoxy/aramid. A simulation of the materials was created using ANSYS Workbench with static and cyclic loading to examine how the materials were expected to fail. The method was based on LEFM and made use of the Maximum Circumferential Stress Criterion to predict where cracks would happen and how they would progress. Normalizing SIFs while a crack was under mixed loading conditions was achieved using the EDI method [84]. We used Paris Law to model fatigue crack growth using constants (C and m) for the materials from previous studies and/or tests. For example, in the case of titanium Grade 2, we found Paris Law constants with C values from 1.8 × 10-10 to 7.9 × 10-12 m/cycle and m values from 2.4 to 4.3, which illustrate differing effects of their
T, Lokesh, Bhaskara Rao, Lokavarapu
Evolution of a Novel Hybrid Stab-Link for a Born Electric Sports Utility Vehicle2026-28-0001To be published on 02/12/2026
The present study details the design evolution and failure analysis of a novel hybrid stabilizer bar link (stab link) developed for the front suspension of a born electric sports utility vehicle (SUV) platform characterized by higher gross vehicle weight (GVW), increased wheel travel, and constrained packaging space. To address these challenges, a unique hybrid stab link was designed featuring dual plastic housings at both the metal ball joint ends, connected by a steel tube, and achieving a 30% weight reduction while offering enhanced articulation angles for extremely lower turning circle diameter (TCD) of the vehicle, compared to the conventional stab link. The unique hybrid stab failed under complex loading conditions during accelerated durability testing (ADT), prompting a comprehensive investigation. The failure analysis included road load data acquisition across various stab bar diameter configurations evolved during suspension tuning, different stabilizer link designs evolved
Selvendiran, P, J, Ramkumar, Nayak, Bhargav, M, Sudhan, Patnala, Avinash
Effect of Sebastiana Rostrata Fiber Loading on the Tribological Behaviour of Polycaprolactone Biocomposite2026-28-0021To be published on 02/12/2026
This study investigates the tribological behaviour of Sesbania rostrata fiber (SRF) reinforced polycaprolactone (PCL) biocomposites using a pin-on-disc wear couple. The stationary SRF/PCL composite specimen interacted with a rotating EN31 steel disc (64 HRC), establishing the sliding wear interface in accordance with ASTM G99 standards. Composite laminates containing 10, 20, and 30 wt% SRF were evaluated at a sliding velocity of 1 m/s over a fixed distance of 1000 m under varying normal loads. The incorporation of SRF significantly enhanced the wear performance relative to neat PCL, with 20 wt% fiber loading achieving the lowest coefficient of friction and specific wear rate due to improved load transfer, stronger interfacial adhesion, and a more uniform laminate structure. In contrast, the 30 wt% composite exhibited fiber agglomeration, reduced homogeneity, and weakened fiber–matrix interactions, resulting in increased wear. SEM microstructural analysis confirmed the formation of a
Raja, K., Senthil Kumar, M.S.
FITTING ASSEMBLY, PLUG, RING LOCKED PORT CONNECTION, 4000 PSI AND 5000 PSIAS5103B (Current)2/6/2026
SCOPE IS UNAVAILABLE.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
CONNECTOR, PLUG, ELECTRIC, CRIMP TYPE, PUSH-PULL COUPLING, SERIES 3 (CLASS L AND E)AS34671C (Current)2/6/2026
SCOPE IS UNAVAILABLE.
AE-8C1 Connectors Committee
Tungsten Disulfide Coating, Thin Lubricating Film, Binder-Less Impingement AppliedAMS2530B (Current)2/6/2026
This specification covers a coating consisting of tungsten disulfide without binders and does not require a curing process.
AMS B Finishes Processes and Fluids Committee
Magnesium Alloy, Extrusions, 6.5Al - 0.95Zn (AZ61A-F), As ExtrudedAMS4350P (Current)2/6/2026
This specification covers a magnesium alloy in the form of extruded bars, rods, wire, tubing, and profiles.
AMS D Nonferrous Alloys Committee
Aluminum Alloy Hand Forgings and Rolled Rings, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061-T652), Solution Heat Treated, Stress Relief Compressed, and Precipitation Heat TreatedAMS4248E (Current)2/6/2026
This specification covers an aluminum alloy in the form of hand forgings up to 8 inches (203 mm), inclusive, in nominal thickness and a cross-sectional area not over 256 square inches (1652 cm2) and rolled rings up to 3.5 inches (89 mm), inclusive, in nominal thickness and with an OD to wall thickness ratio of 10:1 or greater (see 8.6).
AMS D Nonferrous Alloys Committee
Titanium Alloy Bars and Forging Stock, 6.0Al - 2.0Sn - 4.0Zr - 2.0Mo, Duplex AnnealedAMS6905D (Current)2/6/2026
This specification covers a titanium alloy in the form of bars up through 3.000 inches (76.20 mm), inclusive, in diameter or least distance between parallel sides with a maximum cross-sectional area of 10 square inches (64.5 cm2) and forging stock of any size (see 8.7).
AMS G Titanium and Refractory Metals Committee
Plate, Magnesium Alloy, 3.0Al - 1.0Zn - 0.20Mn (AZ31B-H26), Cold Rolled and Partially AnnealedAMS4376J (Current)2/6/2026
This specification covers a magnesium alloy in the form of plate 0.250 to 2.000 inches (6.35 to 50.80 mm), inclusive, in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
Connectors, Electrical, Circular, Miniature, Composite, High Density, Quick Coupling, Environment Resistant, Removable Crimp Contacts Associated Hardware, General Specification forAS29600C (Current)2/6/2026
This SAE Aerospace Standard (AS) covers miniature, composite, high density, threaded coupling, self-locking, circular, environment-resistant, electrical connectors utilizing removable crimp contacts, and associated hardware, which are capable of continuous operation within a temperature range of -65 to +175 °C (-85 to 347 °F). These connectors are supplied under an AS9100 reliability assurance program. See 6.1 for intended use and applications.
AE-8C1 Connectors Committee
Aluminum Alloy, Rolled or Forged Rings, 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr (7075-T7351, 7075-T7352), Solution Heat Treated, Mechanically Stress Relieved, and Precipitation Heat TreatedAMS4311G (Current)2/6/2026
This specification covers an aluminum alloy in the form of rolled or forged rings up to 6 inches (152 mm), inclusive, in nominal thickness at the time of heat treatment and having an OD to wall thickness ratio of 10 or greater (see 8.6).
AMS D Nonferrous Alloys Committee
Aerospace & Defense Technology: February 202626AERP022/5/2026
Plasma Surface Activation for Stronger, More Durable CFRP Bonds in Aerospace Smarter Pyrovalve Alternatives for Modern Missile and Munition Launcher Applications Aerospace Aluminum Laser Welding: Advancing Material Performance for the Future of Flight Model-Based Design Is Shaping the Next Phase of eVTOL Systems Development How RF-over-Fiber is Providing the Backbone of Next Generation Mil/Aero Networks NASA Demonstrates a First-of-Its-Kind Space Communications A Rainfield Simulator for Hypersonic Testing The U.S. Army Space and Missile Defense Command Technical Center's Aerophysics Research Facility, (ARF), fired a successful hypersonic shot to test its new rainfield simulator. Next Generation Carbon Fiber Composites 3D Printer for Hypersonic Research Auburn University's Applied Research Institute in Huntsville is adding some serious fiber to its diet. The Critical Impact Of SAE Aerospace Standards: Certified AS1895/7 and /23 Metal Seals How engineers can ensure safety, reliability
Quality Assurance Sampling and Testing, Carbon and Low-Alloy Steel ForgingsAMS2372J (Current)2/1/2026
This specification covers quality assurance sampling and testing procedures used to determine conformance to applicable specification requirements of carbon and low-alloy steel forgings.
AMS E Carbon and Low Alloy Steels Committee
Steel, Corrosion- and Heat-Resistant, Welding Wire, 16.5Cr - 4.5Ni - 2.9Mo - 0.10N (AM350)AMS5774F (Current)2/1/2026
This specification covers a corrosion- and heat-resistant steel in the form of welding wire.
AMS F Corrosion and Heat Resistant Alloys Committee
Steel, Corrosion-Resistant, Bars, Wire, Forgings, Mechanical Tubing and Forging Stock, 16Cr - 2.5Ni (SAE 51431), Aircraft QualityAMS5628G (Current)1/31/2026
This specification covers a heat-treatable, corrosion-resistant steel in the form of bars, wire, forgings, mechanical tubing, and stock for forging or heading.
AMS F Corrosion and Heat Resistant Alloys Committee
Aluminum Alloy, Alclad Sheet and Plate, 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr, (7075; -T76 Sheet, -T7651 Plate), Solution and Precipitation Heat TreatedAMS4316C (Current)1/31/2026
This specification covers an aluminum alloy in the form of Alclad sheet and plate 0.040 to 1.000 inch, inclusive (1.02 to 25.40 mm, inclusive) in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
Copper-Beryllium Alloy, Bars and Rods, 98Cu - 1.9Be, Solution and Precipitation Heat Treated (TF00, formerly AT)AMS4533F (Current)1/27/2026
This specification covers a copper-beryllium alloy in the form of bars and rods (see 8.5).
AMS D Nonferrous Alloys Committee
INSERT, SCREW THREAD, SHORT, SELF-LOCKING, KEY LOCKED, OVERSIZE SELF-BROACHING KEYS, UNS S66286AS3652A (Current)1/26/2026
E-25 General Standards for Aerospace and Propulsion Systems
Magnesium Alloy, Investment Castings, 10Al (AM100A-T6), Solution and Precipitation Heat TreatedAMS4455J (Current)1/23/2026
This specification covers a magnesium alloy in the form of investment castings (see 8.6).
AMS D Nonferrous Alloys Committee
Plating, CadmiumAMS2400Z (Current)1/23/2026
This specification covers the requirements for electrodeposited cadmium on metal parts.
AMS B Finishes Processes and Fluids Committee
Steel, Welding Wire, 0.65Si - 1.25Cr - 0.50Mo - 0.30V (0.28 - 0.33C) [17-22A(S)], Vacuum Melted, Environment Controlled PackagingAMS6458L (Current)1/23/2026
This specification covers a low-alloy steel in the form of bare welding wire. Type 2 - copper coated wire was removed from this document (see 8.4).
AMS E Carbon and Low Alloy Steels Committee
Steel, Corrosion-Resistant, Investment Castings, 16Cr - 4.1Ni - 0.28Cb - 3.2Cu, Homogenization, Solution, and Precipitation Heat Treated (H900), 180 ksi (1241 MPa) Tensile Strength (17-4)AMS5344H (Current)1/19/2026
This specification covers a corrosion-resistant steel in the form of investment castings homogenized and solution and precipitation heat treated to 180 ksi (1241 MPa) tensile strength.
AMS F Corrosion and Heat Resistant Alloys Committee
Novel Approach on Material Characterization Testing of Various Wiring Harness2026-26-05481/16/2026
The automotive wiring harness (length of 4-5 km) is a very important and complex system in the development of a modern car due to lot of new electric & electronic components and sensors. It is a very sensitive material unlike metals and is considered as a composite which is highly anisotropic in nature, as it consists of several different layers of copper/aluminum strands and insulation. Because of insulation, wiring harness exhibits viscous plastic behavior which is crucial in determining the durability and long-term performance of the cables. Material property has a crucial role in determining the behavior of wiring harness after assembly into the car. Wiring harness may undergo Bending, Torsion and Tension loads, causing the stress and strain in the individual electrical wires. The lack of CAE validation of the wiring harness routing may lead to extra costs for the automotive OEMs during product development. This study explains the novel method of Testing the Cables and Bundles
Beesetti, Siva, Kalkala Balakrishna, Prasad, James Aricatt, John, Shah, Dipam, Tas, Onur, Krogmann, Stephan
Niobium Alloyed Brake Disc for reduced NVH and Emission Control2026-26-02851/16/2026
Recent regulations limiting brake dust emissions have presented many challenges to the brake engineering community. The objective of this paper is to provide a low cost, mass production solution utilizing well known existing technologies to meet brake emissions requirements. The proposed process is to alloy the Gray Cast Iron with Niobium and subsequently Ferritic Nitrocarburize (FNC) the disc. The Niobium addition will improve the wear resistance of the FNC case, reducing wear debris. The test methodology included: 1. Manufacture of disc samples alloyed with Niobium, 2. Finish machining and ferritic nitrocarburizing and 3. Evaluation of airborne wear debris utilizing a pin-on-disc tribometer equipped with emission collection capability. The airborne emission and wear surfaces were further analyzed by Scanning Electron Microscopy, Energy Dispersive techniques (SEM-EDS), X-Ray Diffraction and Optical Microscopy. The cast iron test matrix included four groups; Unalloyed eutectic 4.3
Barile, Bernardo, Holly, Mike
Effect of Flow Forming Process on the Mechanical Properties and Microstructure of GDC & LPDC Cast Aluminium Alloy Wheels2026-26-02981/16/2026
Aluminum alloy wheels have become the preferred choice over steel wheels due to their lightweight nature, enhanced aesthetics, and contribution to improved fuel efficiency. Traditionally, these wheels are manufactured using methods such as Gravity Die Casting (GDC) [1] or Low Pressure Die Casting (LPDC) [2]. As vehicle dynamics engineers continue to increase tire sizes to optimize handling performance, the corresponding increase in wheel rim size and weight poses a challenge for maintaining low unsprung mass, which is critical for ride quality. To address this, weight reduction has become a priority. Flow forming [3,4], an advanced wheel rim production technique, which offers a solution for reducing rim weight. This process employs high-pressure rollers to shape a metal disc into a wheel, specifically deforming the rim section while leaving the spoke and hub regions unaffected. By decreasing rim thickness, flow forming not only enhances strength and durability but also reduces overall
Singh, Ram Krishnan, Medaboyina, HarshaVardhan, G K, Balaji, Gopalan, Vijaysankar, Sundaram, Raghupathi, Paua, Ketan
Review on the Flyback Converter Design for Multi-Output2026-26-02001/16/2026
With the increasing demand for DC loads, DC-DC converters have become indispensable in modern power electronic architectures. With high-voltage applications typical DC-DC converter topologies are required which include isolation for safety and voltage level conversion. Among various isolated converter topologies, the flyback converter is widely favored for low-power applications, typically under 100 W, due to its simplicity and cost-effectiveness. Like other DC-DC topologies, the flyback converter can operate in either continuous conduction mode or discontinuous conduction mode (DCM). The work has focused on the design and performance analysis of a flyback converter operating in DCM, with a specific emphasis on magnetic component design and loss evaluation. A 55 W multi-winding flyback converter employing a passive snubber circuit is studied and implemented. The loss analysis is done with switch losses around 3.4W and the coupled inductor core losses around 1.5W and copper losses
S, Denis, Deshpande, Prathamesh Pravin, Deshpande, Rohan
Non-Metallic Inclusions in Carburizing Steels as a Contributory Factor for the Formation of Carbide Net2026-26-02901/16/2026
The article deals with the issue of identifying structural defects that contribute to the formation of a carbide net during thermochemical treatment of steel parts, which negatively affects the mechanical properties complex of finished products. Based on the available data, a theory has been put forward regarding the influence of the present non-metallic inclusions in the carburizing steels structure on carbide formation process in the hardened layer. As an experimentally the samples have been produced from the varying chemical composition alloy structure carburized steel (0.17-0.23 % C, 0.17-0.37 % Si, 0.80-1.10 % Mn, 1.00-1.30 % Cr, 0.03-0.09 % Ti). During microstructure analysis of the samples it has been establish that non-metallic inclusions, in particular sulfides, contribute to the formation of carbides and carbide net in steel due to their high chemical activity with carbon. Thus, contamination of the metal of carburizing steels with non-metallic inclusions is not only a defect
Runova, Iuliia, Chatkina, Mariia, Musienko, Aleksandr
Life Cycle Assessment of Automotive Cables and GHG Emission Reduction Scenario in Indian Context2026-26-02401/16/2026
Globally, the share of emissions from transport is 15%, out of which more than 2/3rd emissions are contributed by road transport as per 2014 report of Intergovernmental Panel on Climate Change (IPCC). The need of mitigation measures in transport sector has been realised however the study of life cycle emission needs to be done with the tailpipe emissions so that some holistic solution can be worked upon. Strikingly, in the life cycle studies of a passenger car, it was found that the share of raw materials related to copper is around 50% of the total amount of raw material used and the share of copper in the curb weight of vehicle is just 1%. Also, for an Internal Combustion Engine vehicle (ICE), mostly the copper is used in the wiring harness. In this paper, the life cycle assessment of wiring harness is done to understand the environmental impacts throughout the life cycle stages. The comparative study of aluminium alloy and copper has also been done to know the change in
Kumar, Naman, Bawase, Moqtik, Thipse, Sukrut
Design and Development of a Lightweight Aluminium Cascade System for Type IV COPVs for Stationary and Mobile Applications2026-26-04851/16/2026
The global push for clean energy has made hydrogen a central element in decarbonizing transport, industrial processes, and energy systems. Effective hydrogen storage and distribution are critical to supporting this transition, and type IV Composite Overwrapped Pressure Vessels (COPVs) have emerged as the preferred solution due to their lightweight, high pressure capacity, hydrogen embrittlement and corrosion resistance. However, the cascade infrastructure used to house and transport these vessels has lagged behind in innovation. Steel-based cascades, while strong, are heavy prone to corrosion, and unsuitable for mobile deployment. This paper introduces a custom designed aluminium cascade system offering a 65% weight reduction while maintaining structural integrity and safety. Designed for mobile use, the system features modularity, better damping, and enhanced corrosion protection. The paper outlines design methodology, material selection, fabrication process, and comparative
Parasumanna, Ajeet Babu, Muthusamy, Hariprasad, Ammu, Vnsu Viswanath, Kola, Immanuel Raju
Comparative Study of ADC12, A356, and AlSi10Mg Alloys in Sand Casting of EV Battery Housing2026-26-02961/16/2026
This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines
Subramani, Rajesh, Singh, Gajendra, Doddamani, Mrityunjay
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