Browse Topic: Aluminum

Items (4,409)
Monocoque is a kind of integrated shell structure technology, which has gradually become the primary choice for various racing teams to make car bodies because of its advantages of small specific gravity and high specific strength. The unit of the monocoque is a carbon fiber composite sandwich structure, which is composed of two layers of carbon fiber skin inside and outside and core material between them. The inner and outer layers of the carbon fiber skin are stacked with carbon fiber composite materials of different directions and types.In this project, we plan to optimize the shape of the monocoque shell using the surface design software Alias, select core materials of different materials and structures, more advanced layups, and obtain feasible layup sequences and core material types through Ansys simulation and Matlab collaborative optimization, which will be verified by three-point bending experiments. Different from the previous lightweight work based a lot on experience, this
Cheng, Zhu H.Liu, JJ
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, MeysamWang, AndyWang, QiguiYan, Cuifen
Aluminum oxide (Al₂O₃) nanoparticles are considered a promising fuel additive to enhance combustion efficiency, reduce emissions, and improve fuel economy. This study investigates the spray characteristics of diesel fuel blended with aluminum oxide nanoparticles in a constant volume chamber. The blends were prepared by dispersing Al₂O₃ nanoparticles in diesel at varying concentrations (25, 50, and 100 mg of aluminum oxide nanoparticles into 1 L of pure diesel, respectively) using a magnetic stirrer and ultrasonication to ensure stable suspensions. Spray characterization was conducted in a high-pressure and high-temperature constant volume chamber, simulating actual engine conditions. The ambient temperatures for this experiment were set from 800 to 1200 K, and the oxygen concentrations were set from 21% to 13%. The study focused on key spray parameters such as spray penetration length, spray angle, and spray area, analyzed using high-speed imaging and laser diffraction techniques
Ji, HuangchangZhao, Zhiyu
Utilization of fiber-reinforced composite laminates to their full potential requires consideration of angle-ply laminates in structural design. This category of laminates, in comparison with orthotropic laminates, imposes an additional degree of challenge, due to a lack of material principal axes, in determination of elastic laminate effective properties if the same has to be done experimentally. Consequentially, there is a strong inclination to resort to the usage of “CLPT” (Classical Laminated Plate Theory) for theoretically estimating the linear elastic mechanical properties including the cross-correlation coefficients coupling normal and shear effects. As an angle-ply laminate is architecturally comprised of layers of biased orthotropic laminas (based on unidirectional or woven bidirectional fibers), an essential prerequisite for the application of CLPT is an a-priori knowledge of elastic mechanical properties of a constituent lamina. It is natural to expect that the properties of
Tanaya, SushreeDeb, Anindya
Blistering in aesthetic parts poses a significant challenge, affecting overall appearance and eroding brand image from the customer's perspective and blister defects disrupt painting line efficiency, resulting in increased rework and rejection rates. This paper investigates the causes and effects of blistering, particularly in the context of internal soundness of Aluminum castings, emphasizing the crucial role of Computed Tomography in defect analysis. Computed Tomography is an advanced Non-Destructive Testing technique used to examine the internal soundness of a material. This study follows a structured 7-step QC story approach, from problem identification to standardization, to accurately identify the root Cause and implement corrective actions to eliminate blister defect. The findings reveal a strong link between internal soundness and surface quality. Based on the root cause, changes in the casting process and die design were made to improve internal soundness, leading to reduced
D, BalachandarNataraj, Naveenkumar
The improvement of heat dissipation performance of ventilated brake discs is vital to braking safety. Usually, the technical approaches shall be material optimization or structural improvement. In this paper, a simulation model of the heat transfer of brake discs is established using STAR-CCM+ software. Cast iron, aluminum metal matrix composite (Al-MMC), and carbon-ceramic composite materials (C-SiC) are compared. The results show that: Al-MMC has better thermal conductivity so that a more uniform temperature gradient distribution shall be formed; C-SiC has poorer heat capacity yet, according to previous studies, it has better thermal stability, which is the ability to ensure its friction factor under high-temperature condition; cast iron performs better with convective heat transfer rate, which enhances the heat transfer between the surface and surrounding flow field. Based on the results, this paper proposes four types of material combined brake discs using different friction
Wang, JiaruiJia, QingZhao, WentaoXia, ChaoYang, Zhigang
Solid state joining processes are attractive for magnesium alloys as they can offer robust joints without the porosity issue typically associated with welding of magnesium and dissimilar materials. Among these techniques, Self-Piercing Riveting (SPR) is a clean, fast and cost-effective method widely employed in automotive industry for aluminum alloys. While SPR has been proven effective for joining aluminum and steel, it has yet to be successfully adapted for magnesium alloy castings. The primary challenge in developing magnesium SPR technology is the cracking of the magnesium button, which occurs due to magnesium's low formability at room temperature. Researchers and engineers approached this issue with several techniques, such as pre-heating, applying rotation to rivets, using a sacrificial layer and padded SPR. However, all these methods involve the employment of new equipment or introduction of extra processing steps. The aim of this work is to develop a SPR technique which adapts
Tabatabaei, YousefWang, GerryWeiler, Jonathan
Given the strategic importance of aluminum cast materials in producing lightweight, high-performance products across industries, it is fundamental to assess their mechanical and cyclic fatigue properties thoroughly. This investigation is primarily for optimizing material utilization and enhancing the efficiency and reliability of aluminum cast components, contributing to significant conservation of raw materials and energy throughout both the manufacturing process and the product's lifecycle. In this study, a systematic material investigation was conducted to establish a reliable estimation of the fatigue behavior of different aluminum cast materials under different loading ratios and elevated temperatures. This paper presents an analysis of the statistical and geometrical influences on various aluminum alloys, including AlSi10MnMg, AlSi7Mg0.3, and AlSi8Cu3Fe, produced via pressure die casting and gravity die casting (permanent mold casting), and subjected to different heat treatment
Qaralleh, AhmadNiewiadomski, JanBleicher, Christoph
This specification covers the requirements of uncoated aluminum alloy foil for core materials required for structural sandwich construction.
AMS D Nonferrous Alloys Committee
This test procedure defines a laboratory procedure for generating and evaluating filiform corrosion on painted aluminum wheels and painted aluminum wheel trim. While this test was developed specifically for the testing of painted aluminum wheels and wheel trim, it may be applicable to other components. The application owner will need to assess if this test generates filiform similar to that found in the relevant usage to ensure it will provide accurate data for the application.
Wheel Standards Committee
This specification covers an aluminum bronze alloy in the form of bars, rods, forgings, and forging stock.
AMS D Nonferrous Alloys Committee
The present study is focused on the integration of phase change materials (PCMs) and Al2O3 nanoparticles into solar stills presents a promising approach to enhance their efficiency. This paper explores the design and performance analysis of a solar still system incorporating PCMs and Al2O3 nanoparticles with different concentration like 200ppm and 400ppm. The primary goal is to investigate the impact of these enhancements on the solar still’s productivity and thermal efficiency.The Aluminium Oxide Nanoparticle were synthesized by chemical co-precipitation method. XRD and TEM were used to characterize the aluminum oxide particles. In this study, Aluminum oxide nanoparticles were employed as thermal conductivity materials, while TN+30 were utilized as a phase change material. After taking about 25 (liters) of water, it was discovered that 1 cm was the ideal depth. Compared to PCM, the energy materials TN+30 and Al2O3 increased collection efficiency with 200 ppm and 400 ppm of 21.65% and
R L, KrupakaranSagaya Raj, GnanaPetla, Ratna KamalaKala, Lakshmi KAnchupogu, Praveen
This study investigates the fabrication and characterization of overhanging structures using the Cold Metal Transfer (CMT) pulse based Wire Arc Additive Manufacturing (WAAM) technique, specifically targeting automotive applications on commercial aluminum components. Focusing on optimal welding strategies for overhanging structures, components are fabricated by providing offsets during consecutive deposition of layers, thus producing parts with angles of 45°, 60° and 90° inclinations from the substrate. Three specimens undergo around twenty-five layers of deposition, resulting in structurally sound joints within this specified angle range. AA 4043 electrode is utilized, and welding parameters are optimized through trials by verifying with bead on plate deposition. Successful outcomes are achieved within the specified angle range, though challenges arise beyond 60°, complicating the maintenance of desired weld quality. The study further evaluates the microstructure, microhardness, and
A, AravindS, JeromeA, Rahavendran
Aluminum Matrix Composites (AMCs) are gaining traction in aerospace, automotive, and marine industries due to their superior mechanical properties. By integrating hard ceramic particles such as silicon carbide (SiC) and aluminum oxide (Al₂O₃) into aluminum matrices, these composites exhibit enhanced wear resistance and strength-to-weight ratios. This study explores the fabrication and characterization of 6061-T6 aluminum alloy matrix composites, reinforced individually with SiC and Al₂O₃ particles through the squeeze casting technique. The research includes a comprehensive analysis of microstructures and mechanical properties, focusing on compressive strength, Brinell hardness, and tribological behavior. Findings reveal that SiC and Al₂O₃ reinforcements boost compressive strength by up to 27% and 47%, respectively, and increase hardness by up to 29% and 20%, respectively, compared to unreinforced aluminum.
Thirumavalavan, R.Santhosh, V.Sugunarani, S.Regupathi, S.Sundaravignesh, S.
This research was conducted with the aim of exploring the usage of advanced lightweight materials such as aluminum matrix composite and aramid fiber reinforcement polymer for increased structural integrity of the hood of an automotive vehicle. The automotive sector is moving toward lightweight materials because of the need to enhance fuel efficiency, the importance of reducing environmental impact, and the need to ensure safety of new-generation automobiles. While traditional materials such as steel and aluminum might be very rigid and durable, they also add huge weight to the overall vehicle design. Consequently, these vehicles become more fuel inefficient, which could lead to higher emissions and pollution. The two materials chosen for this research are very promising, considering that both are characterized by high specific strength and impact resistance capabilities. The low weight of the materials is also an added bonus. While AMC is manufactured by consolidating aluminum with
Arvinda Pandian, C.K.Balaji, N.Seeniappan, KaliappanNatrayan, L.Maranan, RamyaRavi, D.
Wear-resistant, die-cast B390 aluminum represents a relevant material frequently used in the automotive industry. The wear and its relation to the microstructure along with different alloying additives is studied with efforts toward improved performance. Alloying by Sr allows for a lower Fe content helps in mitigating iron needling. This paper addresses wear performance of B390 and Sr-modified B390 alloys, tested against pearlitic cast iron, used for manufacture of piston rings. The wear tests were designed by using an ASTM G99 standardized pin-on-disc protocol at “wet” (motor oil) and “dry” conditions and were performed using a UMT (Bruker) benchtop tester. The polished cross-sections and friction surfaces were studied to identify the microstructural differences and dominating wear mechanisms. Interestingly, the stronger and harder Sr-modified B390 alloys wear more at dry conditions compared to the standard die-cast B390 alloy. This was ascribed to a change in wear mechanisms of the
Kancharla, Sai KrishnaJogineedi, RohitSingireddy, Vishal ReddyMirzababaei, SaerehDierks, MikeFilip, Peter
Grain refinement of aluminium and its alloys is a common industrial practice, particularly for automobile casting. The grain refines with titanium agent influence better mechanical behaviour such as higher yield and ultimate tensile strength rather than monolithic alloy. Present study, the halide salt method has been used to produce the Al-Ti-B grain refiners with different Ti/B ratios. The prepared grain refiner is added in A356 alloy and observed its grain refining efficiency. The addition of grain refiner to A356 aluminium alloy at different holding times, such as 10, 20, and 30 min, allowed it to solidify. It is found that 30 min of holding time with 5Ti1B improves the hardness (40%) and ultimate tensile strength (UTS) value (63.56%). A high degree of grain refinement was observed in a 30-minute holding time with 5Ti1B with improved grain refining efficiency of 3 %. Its microstructural observation and tensile properties helped us understand this grain refinement.
Venkatesh, R.Manivannan, S.Das, A. DanielMohanavel, VinayagamSoudagar, Manzoore Elahi Mohammad
The AA2024 aluminum alloy is a precipitate-hardening material renowned for its exceptional strength and corrosion resistance, making it a preferred choice for various applications in industries such as aircraft and automobile manufacturing. However, it is challenging to weld using fusion welding processes due to differences in melting points between the aluminum base material and its oxide layer. Consequently, this often results in issues such as partially melted zones, alloy segregation, and hot cracking. In this investigation, electron beam welding was employed to minimize heat input and prevent the formation of coarse grains in the heat-affected zone. Observations revealed that the joint achieved a maximum strength of 285 MPa, representing 62% of the base material's strength. This improvement in strength can be ascribed to the establishment of fine and recrystallized grains at the weld interface, along with the presence of copper aluminide strengthening precipitates.
Rajesh, A.Karthick, S.Mallieswaran, K.Shanmugam, Rajasekaran
Growing demand for fuel-efficient vehicles and lower CO2 emissions has led to the development of lightweight materials. Aluminum composites are being used to achieve lightweighting to improve performance, efficiency, and sustainability across various industries. The unique properties of aluminum composites make them an attractive choice for researchers and designers looking to optimize their products. Reinforcement materials play a vital role in the development of these composites, acting as barriers to dislocation movement within the aluminum matrix. This effectively strengthens the material and prevents deformation under load, resulting in increased tensile strength and fatigue resistance. Additionally, aluminum composites exhibit improved thermal and electrical conductivity, making them suitable for automotive applications. In this study, metal matrix composites (MMCs) of aluminum 7075 alloys were developed using silicon carbide (SiC) and flyash as reinforcements. Three different
Manwatkar, Asmita AshokSantosh Jambhale, MedhaMahagaonkar, NitinSharma, Dipesh
To meet light-weighting and safety target of automotive vehicles, different Aluminium alloys are used in various body parts. Apart from conventional manufacturing process of gravity die casting (GDC), advanced manufacturing process such as low pressure die casting (LPDC), high pressure die casting (HPDC) and extrusion processes are also used to form complex automotive body parts. Steel parts are majorly used in automotive applications across world. However, steel has limitations with respect to light-weighting. To achieve light-weighting, now a days, there is trend to use these complex Aluminium parts in automotive industry to replace steel and integrate multiple parts into a single one. Aluminium has emerged as great potential for light-weighting and reducing complexity of handling multiple parts at an automotive plant. There is a challenge to identify suitable etchant for microstructural characterization of Aluminium alloy parts that can be made through various manufacturing
Deshmukh, MansiJain, VikasMisal, SwapnaliPaliwal, Lokesh
Aluminum alloys serve a critical role in the aerospace industry, accounting for a significant amount of commercial aircraft weight. Despite the growing use of composite materials, aluminum remains important in airframe construction due to its lightweight, cost-effectiveness, and high strength potential. Structural integrity is critical in modern engineering, necessitating early diagnosis and localization of damage. To detect the flaws, cracks, and cut-out in the structures, structural health monitoring (SHM) systems are essential, with non-destructive testing (NDT) methodologies playing critical roles. Among these technologies, ultrasonic guided wave testing (UGWT) has gained popularity because of its capacity to propagate over long distances and detect subsurface faults. This article investigates the use of UGWs to identify cut-outs in aluminum plates. The numerical investigation has been carried out using commercially available finite element software Abaqus. The ultrasonic lamb
Rajput, ArunPatil, Vaibhav KailasBhosale, AniketYadav, RiteshGhatge, AdityarajPandey, Anand Ji
Recent developments in manufacturing techniques and the development of Al7075 metal matrix composites (MMCs) with reinforcements derived from industrial waste have been steadily gaining popularity for aerospace and automobile applications due to their outstanding properties. However, there are still a lot of limitations with these composite materials. A great deal of research has been done to create new Al7075 MMC materials with the use of economic fly ash (FA) that possesses superior mechanical properties, corrosion resistance, density, and cycle cost. This review outlines different synthesis techniques used in the development of Al7075 MMCs using stir casting. Effects of FA along with other reinforcements on the mechanical, wear, machining, and microstructural properties of the composite are also discussed. Finally, a summary of the application of FA-based MMCs and a recap of the previous discoveries and challenges are reported. Future scope and potential areas of application are
Kumar, RandhirMondal, Sharifuddin
This specification covers aluminum and aluminum alloy foil in the form of laminated sheet (see 8.6).
AMS D Nonferrous Alloys Committee
In the fall of 2023, NASA hot fire tested an aluminum-based, 3D-printed rocket engine nozzle. What made the event remarkable is that aluminum isn’t typically used for additive manufacturing because the process causes it to crack, and it isn’t used in rocket engines due to its low melting point. Yet the test was a success.
Eight arguments for these resins, compounds and composites. Weight reduction in EV battery components is an important factor in optimizing battery energy density, which in turn is critical to extending vehicle range and boosting power and performance. Although traditional metals such as steel and aluminum are widely used in EV batteries, the ongoing push for higher energy density is opening new opportunities for thermoplastic resins, compounds, and composites. The main advantage of these materials vs. metals is their inherent lighter weight - particularly in the case of lower-density polymers. Thermoplastics can be 30-50 percent lighter than metals. They also increase design freedom, which permits further weight-out through part consolidation and thin walls.
Bobba, Somasekhar
The essential aspect of an automobile is its braking system. Brakes absorb the kinetic energy of the rotating parts, i.e., wheels, and dissipate this energy into the surroundings in the form of heat. This entire process is quite complex, and the brake disc is subjected to extreme thermal and structural stresses along with deformation, which might damage the disc. This paper presents a structural and thermal analysis of an Audi Q3 brake disc using an ANSYS 2021-R1. The present brake disc is designed using SOLIDWORKS software. Composite materials are added in the ansys material library by adding their respective characteristics. The thermal analysis mainly focused on temperature variation and directional heat flux. The structural study was conducted to understand the stresses developed during braking and the deformations observed. Along with a comprehensive structural and thermal analysis, this work has also estimated the life of the brake disc, the factor of safety, and the real-time
Bahulekar, AtharvShiralkar, ShaunakJomde, AmitShamkuwar, SonalPatane, PrashantShinde, TarangDandin, Shahbaz
This SAE Aerospace Recommended Practice establishes the requirements and procedures for eddy current inspection of open fastener holes in aluminum aircraft structures.
AMS K Non Destructive Methods and Processes Committee
This specification covers an aluminum bronze alloy in the form of sand castings (see 8.5).
AMS D Nonferrous Alloys Committee
Military performance requirements for adhesives have been traditionally derived to fulfill niche defense needs in harsh operational environments with little consideration for dual-use commercial potential. U.S. Army Research Laboratory, Aberdeen, MD The term “military-grade” can have a variety of meanings that are perspective dependent. In 2014, Ford Motor Company emphasized the term heavily in advertising campaigns to garner consumer acceptance for the transition from steel to aluminum in the body of their flagship F150 model. As cited by Ford, “Engineers selected these high-strength, military-grade aluminum alloys because of the metals' unique ability to withstand tough customer demands.” From this point-of-view, military-grade implies superior performance. However, the bureaucratic and logistical barriers required for certification to military-grade acceptance levels per DoD performance requirements can also be perceived as impediments to innovation and the transition of fundamental
The term “military-grade” can have a variety of meanings that are perspective dependent. In 2014, Ford Motor Company emphasized the term heavily in advertising campaigns to garner consumer acceptance for the transition from steel to aluminum in the body of their flagship F150 model. As cited by Ford, “Engineers selected these high-strength, military-grade aluminum alloys because of the metals’ unique ability to withstand tough customer demands.” From this point-of-view, military-grade implies superior performance. However, the bureaucratic and logistical barriers required for certification to military-grade acceptance levels per DoD performance requirements can also be perceived as impediments to innovation and the transition of fundamental science into tangible product. This is in-part due to the legacy age of many DoD performance standards dating to the 1950s and 1960s when the US military peaked in technology market share and was responsible for approximately two-thirds of domestic
While Daimler Truck and Paccar are pursuing LFP battery cells, Volvo Trucks employs lithium-ion batteries in which lithium nickel cobalt aluminum oxide (NCA) is used as the cathode — for now anyway. The Swedish truck maker is continuously exploring other battery technologies.
Demands for new materials with superior properties are rising as technological advancement is speeding up globally. Composite materials are gaining popularity due to their enhanced mechanical properties over metal and alloys. Aluminum metal matrix composites (MMCs) are becoming popular in several areas of application such as aerospace, automobile, armed forces, and other commercial applications due to their lightweight, increased strength, better fracture toughness, stiffness, corrosion resistance, and cost-effectiveness. The present study reviews the effects of different reinforcements on MMC materials. The main aim of the present work is to give a clear idea to the readers about the role of individual reinforcement in Al7075-based MMCs. Also, the details of weight% and size of different reinforcement are provided, which will help the readers in their future works. It has been observed that inorganic reinforcements give better mechanical and wear properties to composite materials. For
Kumar, RandhirMondal, Sharifuddin
The use of aluminum to manufacture injection molds aims to maximize the productivity of plastic parts, as its alloys present higher heat conductivity than tool steel alloys. However, it is essential to accurately control the injection molding parameters to assure that the design tolerances are achieved in the final molded plastic part. The purpose of this research is to evaluate the use of aluminum alloys in high-volume production processes. It delves into the correlation between the type of material used for mold production (steel or aluminum) and the thickness of the injected part, and how these variables affect the efficiency of the process in terms of the quantity and quality of the produced parts. The findings suggest that replacing steel molds with aluminum alloys significantly reduces injection molding cycle time, the difference ranging from 57.1% to 72.5%. Additionally, the dimensional accuracy and less distortion provided by aluminum have improved product quality. In case of
Marconi, PedroAmarante, EvandroFerreira, CristianoBeal, ValterRibeiro Júnior, Armando
This SAE Aerospace Information Report (AIR) is intended to be used as a process verification guide for evaluating implementation of key factors in repair of metal bond parts or assemblies in a repair shop environment. This guide is to be used in conjunction with a regulatory approved and substantiated repair and is intended to promote consistency and reliability.
AMS CACRC Commercial Aircraft Composite Repair Committee
This specification establishes the requirements for a hard anodic coating on aluminum and aluminum alloys.
AMS B Finishes Processes and Fluids Committee
This article presents a strategy for the virtual calibration of a large-scale model representing a self-piercing rivet (SPR) connection. The connection is formed between a stack of three AA6016-T4 aluminum sheets and one SPR. The calibration process involves material characterization, a detailed riveting process simulation, virtual joint unit tests, and the final large-scale model calibration. The virtual tests were simulated by detailed solid element FE models of the joint unit. These detailed models were validated using experimental tests, namely peeling, single-lap joint, and cross-tests. The virtual parameter calibration was compared to the experimental calibration and finally applied to component test simulations. The article contains both experiments and numerical models to characterize the mechanical behavior of the SPR connection under large deformation and failure.
André, VictorCostas, MiguelLangseth, MagnusMorin, David
Multiple experimental studies were performed on galling intiation for variety of tooling materials, coatings and surface treatments, sheet materials with various surface textures and lubrication. Majority of studies were performed for small number of samples in laboratory conditions. In this paper, the methodology of screening experiment using different combinations of tooling configurations and sheet material in the lab followed by the high volume small scale U-bend performed in the progressive die on the mechanical press is discussed. The experimental study was performed to understand the effect of the interface between the sheet metal and the die surface on sheet metal flow during stamping operations. Aluminum sheet AA5754 2.5mm thick was used in this experimentation. The sheet was tested in laboratory conditions by pulling between two flat insert with controllable clamping force and through the drawbead system with variable radii of the female bead. Comparing pulling forces during
Reinberg, NataliaMurray, RyanAscencio Barrera, SindiPineda Carranza, CristinaGolovashchenko, Sergey
As data science technologies are being widely applied on various industries, the importance of data itself increased. A typical manufacturer company has a vast data set of products as 2D&3D drawing formats, but a common problem was that building a database from the 2D&3D drawings costs much, and it is hard to update the database after it once built. Also, it is high-cost job when the new factor researched and necessary to investigate the new factors on previously fixed or uploaded drawings. As new products are developed with time, these problems are getting more difficult. In this paper, an automated database building method using CATIA introduced and future probabilities are suggested. An aluminum wheel part was used as an example. An automated logic used CATIA V5’s VBA functions and was handled by python programming language. Product database was established by using the automated logic for extracting engineering design features, and data mining process was deployed based on the
Seo, JeonginJang, YoungseokSeo, MyoungkyuYum, Kiho
Battery packs of electric vehicles are typically composed of lithium-ion batteries with aluminum and copper acting as cell terminals. These terminals are joined together in series by means of connector tabs to produce sufficient power and energy output. Such critical electrical and structural cell terminal connections involve several challenges when joining thin, highly reflective and dissimilar materials with widely differing thermo-mechanical properties. This may involve potential deformation during the joining process and the formation of brittle intermetallic compounds that reduce conductivity and deteriorate mechanical properties. Among various joining techniques, laser welding has demonstrated significant advantages, including the capability to produce joints with low electrical contact resistance and high mechanical strength, along with high precision required for delicate materials like aluminum and copper. The primary objective of this study was to join 0.8 mm thick aluminum
Ko, Byung MinGryguc, AndrewChen, JimHunt, JustinGuo, MingchaoZhang, WenshengJahed, HamidGerlich, Adrian
Electrification is the future of the automotive industry and with the rapid growth of Battery Electric Vehicle (BEV) market, battery protection becomes more and more crucial. Side pole impact is one of the most challenging safety load cases. Rocker assembly, as the first line of defense, plays a significant role during the event. This paper proposes Cleveland-Cliffs Steel Tube as Reinforcement (C-STARTM) protection as an application for rocker reinforcement. For a component level assessment, three-point bending is used as a testing method to replicate pole impact. The performance is compared with aluminum baseline with respect to peak force and energy absorption. Test and CAE simulations have been performed and a well calibrated CAE model is utilized to predict the robustness of various steel designs using different grades, gauges and geometries. It is shown that C-STARTM [1] protection is a scalable and configurable solution that offers superior performance in terms of peak force and
Yu, MiaoHu, JunZhu, FengNazari, Sobhan T.Elengikal, SajanMakrygiannis, JohnZhang, JimmyWang, Yu-WeiStubleski, DawnLuther, Isaac
The design of lightweight vehicle structures has become a common method for automotive manufacturers to increase fuel efficiency and decrease carbon emission of their products. By using aluminum instead of steel, manufacturers can reduce the weight of a vehicle while still maintaining the required strength and stiffness. Currently, Resistance Spot Welding (RSW) is used extensively to join steel body panels but presents challenges when applied to aluminum. When compared to steel, RSW of aluminum requires frequent electrode cleaning, higher energy usage, and more controlled welding parameters, which has driven up the cost of manufacturing. Due to the increased cost associated with RSW of aluminum, Refill Friction Stir Spot Welding (RFSSW) is being considered as an alternative to RSW for joining aluminum body panels. RFSSW consumes less energy, requires less maintenance, and produces more consistent welding in aluminum as compared to RSW. Research has shown that RFSSW is capable of
Gale, DamonHovanski, YuriCoyne, JeremyNamola, Kate
Items per page:
1 – 50 of 4409