Browse Topic: Ferrous metals

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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
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
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
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
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
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
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
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
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
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
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
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
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
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
Steel, Corrosion-Resistant, Bars, Wire, Forgings, Mechanical Tubing, and Rings 16Cr - 4.0Ni - 0.30Cb - 4.0Cu Solution Heat Treated, Precipitation Hardened (H1025) Consumable Electrode RemeltedAMS5622/H1025A (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 (H1025) 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 (H1150)AMS5622/H1150 (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 (H1150) 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 (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
Steel Bars, Wire, Forgings, Mechanical Tubing and Forging Stock, Corrosion Resistant 14Cr - 2.1Mo - 0.30Cb (Nb) - 1.0V (1.05 - 1.15C) Premium Aircraft Quality for Bearing Applications, Double Vacuum Melted, AnnealedAMS5900D (Current)02/25/2025
This specification covers a premium aircraft-quality, corrosion-resistant steel in the form of bars, wire, forgings, mechanical tubing, and forging stock.
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 (H1100)AMS5622/H1100 (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 (H1100) 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 (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
Steel, Sheet, Strip, and Plate 0.80Cr - 1.8Ni - 0.25Mo (0.38 - 0.43C) (SAE 4340). Aircraft QualityAMS6359M (Current)02/25/2025
This specification covers an aircraft-quality, low-alloy steel in the form of sheet, strip, and plate.
AMS E Carbon and Low Alloy Steels Committee
Material Specification
Steel, Corrosion- and Heat-Resistant, Welding Wire 9.0Mn - 20Cr - 6.2Ni - 0.20N (21-6-9, Nitronic® 40W)AMS5818D (Current)02/25/2025
This specification covers a corrosion- and heat-resistant steel in the form of welding wire.
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Multi-Objective Optimization of Powder-Mixed Electro-Discharge Machining of Tool Steel Using Advanced Algorithm05-18-03-002102/20/2025
Electrical discharge machining (EDM) technology is one of the unconventional machining processes with an ability to machine intricate geometrics with micro finishing. Powder-mixed EDM (PMEDM) extends the EDM process by adding conductive powder to the dielectric fluid to improve performance. This set of experiments summarizes the effect of brass and copper electrode on HcHcr D2 tool steel in chromium powder-mixed dielectric fluid. Powder concentration (PC), peak current (I), and pulse on-time (Ton) are considered as variable process parameters. General full factorial design of experiment (DOE) and ANOVA has been used to plan and analyze the experiments where powder concentration is observed as the most significant process parameter. The results also reveal that a brass electrode offers a high material removal rate (MRR). Whereas, the copper electrode has reported noteworthy improvement in surface roughness (Ra). Moreover, teaching–learning-based optimization (TLBO) algorithm has been
Sonawane, Gaurav Dinkar, Sulakhe, Vishal, Dalu, Rajendra, Kaware, Kiran, Motwani, Amit
Journal Article
SHIELD BAND, CONNECTOR ACCESSORIES, ELECTRICAL BACKSHELL, CATEGORY 7 (FOR AS85048/82 - /90, /93, /109 - /117 ACCESSORIES)AS85049/128G (Current)02/08/2025
AE-8C1 Connectors Committee
Technical Standard
CONNECTOR ACCESSORIES, ELECTRICAL, STRAIN RELIEF, 90°, CATEGORY 4C (FOR MIL-DTL-24308 CONNECTORS)AS85049/50E (Current)02/08/2025
AE-8C1 Connectors Committee
Technical Standard
CONNECTOR ACCESSORIES, ELECTRICAL, STRAIN RELIEF, STRAIGHT SELF-LOCKING, AND NON-SELF-LOCKING, CATEGORY 4C (FOR MIL-DTL-38999 SERIES I AND II CONNECTORS)AS85049/121C (Current)02/08/2025
AE-8C1 Connectors Committee
Technical Standard
Crash Performance Study on High-Speed Electric Two-Wheeler Battery Enclosure2025-28-020302/07/2025
The usage of Electric Vehicles (EVs) and the annual production rate have increased significantly over the years. This is due to the development of rechargeable electrical energy storage system (battery pack), which is the main power source for EVs. Lithium-ion batteries (LIBs) pack is predominantly used across all major vehicle categories such as 2-wheelers, 3-wheelers and light commercial vehicle. LIB is one of the high energy-dense sources of volume. However, LIBs have a challenge to pose a risk of short circuits and battery pack explosions, when exposed to damage scenarios. In the present study, the controlled crash analysis is performed for various velocities ranging from 50 kmph to 72 kmph against an obstruction directly and at an offset from the wheel, so as to mimic the real-world crash of high-speed two-wheelers. The behavior of the battery enclosure is examined through evaluating the structural integrity of the battery enclosure used in a realistic two-wheeler after crash at
Venkatesan Sr, Aiyappan, Nelson, N Rino, Hariharan Nair, Adarsh
Technical Paper
Steel Sheet, Strip, and Plate 0.95Cr - 0.20Mo - (0.38 - 0.43C) (SAE 4140) Aircraft QualityAMS6395K (Current)02/07/2025
This specification covers an aircraft-quality, low-alloy steel in the form of sheet, strip, and plate.
AMS E Carbon and Low Alloy Steels Committee
Material Specification
Effect of Hardening and Tempering Temperatures on the Mechanical Behavior of Alloy Steel2025-28-002702/07/2025
Alloy steel possesses high strength, hardenability, fatigue strength, and good impact toughness. It is widely used for making various machine parts, automobile components, shafts, gears, connecting rods, and more. Hardening and tempering develop the optimum combination of hardness, strength, and toughness in engineering steel, thereby providing components with high mechanical properties. Hardening and tempering temperatures are crucial factors that affect the mechanical and metallurgical properties of 42Cr4Mo steel. In this research work, 42Cr4Mo alloy steel samples were subjected to hardening and tempering processes. The hardening temperatures were set at 830°C, 850°C, and 870°C, while the tempering temperatures were maintained at 590°C and 650°C. The test results show that hardening at 830°C and tempering at 590°C achieve high tensile strength, which decreases as the temperature increases. Different hardening temperatures and constant tempering temperatures will be optimized to
Murugesan, Venkatasudhahar, Ganesan, Dharmalingam, Tarigonda, Hariprasad
Technical Paper
Evaluation on Mechanical and Metallurgical Properties of Wire Arc Additive Manufactured ER 2209 Duplex Stainless Steel for Automotive and Marine Applications2025-28-010802/07/2025
The advancement of wire-arc additive manufacturing (WAAM) presents a significant opportunity to revolutionize the production of automotive components through the fabrication of complex, high-performance structures. This study specifically investigates the metallurgical, mechanical, and corrosion properties of WAAM-fabricated ER 2209 duplex stainless steel structures, known for their superior mechanical properties, excellent corrosion resistance, and favorable tribological behavior. The research aims to optimize WAAM process parameters to achieve high-quality deposition of ER 2209, ensuring structural integrity and performance suitable for both marine and various automotive applications. Microstructural analysis of the produced samples revealed the alloy’s dual-phase nature, with roughly equal amounts of ferrite and austenite phases uniformly mixed across the layers of deposition. This balanced microstructure contributes to the alloy’s excellent mechanical properties. Yield strength
A, Aravind, S, Jerome, Kumar, Ravi
Technical Paper
Optimization of Wire Electrical Discharge Machining Parameters for Invar 36 Material Using Regression Modeling2025-28-012202/07/2025
Wire Electrical Discharge Machining (WEDM) is a sophisticated machining technique that offers significant advantages for processing materials with elevated hardness and complex geometries. Invar 36, a nickel-iron alloy characterized by a reduced coefficient of thermal expansion, is extensively used in the aerospace, automotive, and electronic sectors due to its superior dimensional stability across a wide temperature range. The primary goals are to improve machining settings and develop regression models that can precisely predict critical performance metrics. Experimental experiments were conducted using a WEDM system to mill Invar 36 under diverse machining parameters, including pulse-on time, pulse-off time, and current setting percentage (%). The machining performance was assessed by quantifying the material removal rate (MRR) and surface roughness (Ra). The design of experiments (DOE) methodology was used to systematically explore the parameter space and identify the optimal
Pasupuleti, Thejasree, Natarajan, Manikandan, Raju, Dhanasekar, Krishnamachary, PC, Silambarasan, R
Technical Paper
Design and Optimization of Low-Budget Yokeless and Segmented Armature Electrical Machine2025-01-705501/31/2025
This paper designs a low-budget yokeless and segmented armature (YASA) axial flux permanent magnet synchronous machine, which replaces some of the PMs attached to the rotor with silicon steel plates. For the purpose of checking the effectiveness of the proposed machine, the equivalent magnetic circuits of the typical and proposed YASA machines are first compared and analyzed, and then the models of the two machines are constructed and simulated. The results prove that the proposed YASA machine significantly reduces the quantity of permanent magnets compared to the typical machine. In addition, the thickness of the machine rotor disc has been reduced by optimizing the machine, which both enhances the power density and reduces the volume of the machine. Finally, the rotor-stator magnetic pulling force of the machine is simulated and analyzed, and the results prove that the proposed machine can operate stably.
Li, Tao, Wang, Bitan, Diao, Chengwu, Zhao, Wenliang
Technical Paper
Microstructure and Strength of Zinc-Molybdenum Steel Joints Brazed with Nickel-Chromium-Zinc Filler Metal2024-01-525501/28/2025
Intermetallic Zn-Mo to steel induction brazing was performed in an induction furnace at 1260 degrees Celsius for 0.8 thousand seconds utilising Ni-Cr-Zn filler metal. Base metal atoms such as zinc, molybdenum, and nickel are stated to diffuse to the contact and aggressively react with the filler metal during brazing. This is backed by microstructural research. The reaction layer near Zn-Mo, which is composed of Ni-Cr-Zn compounds and Ni-based solid solutions; the interface's centre zone, which is composed of Ni-based solid solutions with distributed Ni-Cr eutectic phases; and the NiC reaction layer near the steel. The interface is made up of all of these components. The best values for the induction brazing parameters may be calculated by analysing the association between the brazing parameters and the tensile strength of the joints. The joint has a tensile strength of 348 MPa after being brazed at a temperature of 1260 degrees Celsius for 0.8 thousand seconds.
Babu Chellam, B Ashok Kumar, Vimal Raja, M., Dhiyaneswaran, J., Selvaraj, Malathi, Sangeeth Kumar, M.
Technical Paper
Advancements in Lightweight Composite Materials for Enhancing the Structural Integrity of Automotive Component2025-01-500501/23/2025
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, Kaliappan, Natrayan, L., Maranan, Ramya, Ravi, D.
Technical Paper
Carburizing Steel Alloy, Powder for Additive Manufacturing 3.5Cr - 7.5Ni - 16.3Co - 1.75Mo - 0.2W - (0.10 - 0.15 C)AMS7055 (Current)01/22/2025
The intended upper bound of this specification is that the particle size distribution (PSD) of powders supplied shall be <60 mesh (250 µm) and that no powder (0.0 wt.%) greater than 40 mesh (425 µm) is allowed.
AMS AM Additive Manufacturing Metals
Material Specification
Steel Sheet, Strip, and Plate, Low Alloy, Heat-Resistant 0.65Si - 1.25Cr - 0.50Mo - 0.25V (0.27 - 0.33C) [17-22A(S)] Aircraft QualityAMS6385M (Current)01/22/2025
This specification covers an aircraft-quality, low-alloy steel in the form of sheet, strip, and plate.
AMS E Carbon and Low Alloy Steels Committee
Material Specification
Steel, Corrosion Resistant, Sheet, Strip, and Plate 18Cr - 8.5Ni (302) Solution Heat Treated, High DuctilityAMS5515P (Current)01/22/2025
This specification covers a corrosion-resistant steel in the form of sheet, strip, and plate over 0.005 inch (0.13 mm) in nominal thickness.
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Investigating the Orientation-Dependent Mechanical Properties and Microstructure of 304L Austenitic Stainless Steel Fabricated via Wire Arc Additive Manufacturing2025-01-500101/15/2025
Additive manufacturing technologies, particularly wire arc additive manufacturing (WAAM), have gained recognition for their ability to produce large metallic components efficiently and cost-effectively. This study investigates both the mechanical properties and microstructure of 304L austenitic stainless steel produced via WAAM, focusing on orientation-dependent behavior. Tensile specimens were prepared in transversal, diagonal, and longitudinal orientations according to ASTM E8 standards, and their mechanical properties were evaluated. The results show that the diagonal sample exhibited the highest tensile strength of 555 MPa with an elongation of 47.9%, while the longitudinal sample demonstrated the highest ductility with a notable elongation of 61.4%. Microstructural analysis, including scanning electron microscopy (SEM), revealed refined grain structures and alignment that influenced mechanical properties and stress distribution. Hardness measurements showed an increase across all
Navaneethasanthakumar, S., Suresh, R., Santhosh, V., Godwin Raja Ebenezer, N., Sankarapandian, S.
Technical Paper
Porosity Effect on the Scratch Tests of Austenitic Stainless Steel (AISI 316L)2024-36-011212/20/2024
Austenitic stainless steel (AISI 316L) is highly valued in various industries for its properties, especially related to wear and corrosion resistances. There are several applications of austenitic stainless steel in the automotive industry. This study investigates the effects of porosity of SS316L samples fabricated using powder metallurgy (uniaxial pressure). Two different compaction pressures, 300 MPa, and 600 MPa, were applied to analyze their influence on the material’s density, porosity, microstructure, hardness, and abrasion responses. The SS316L samples were sintered at 1120 °C for 30 min. The microstructural analysis revealed that the sample pressed at 600 MPa exhibited higher density and lower porosity (18.9%) compared to the sample pressed at 300 MPa (29.2%). This increased compaction pressure led to a more uniform microstructure with smaller grain sizes and a more consistent distribution of circular pores. Consequently, the hardness of the 600 MPa sample was significantly
Tahanzadeh, Samira, Seriacopi, Vanessa, Rodrigues, Daniel, Machado, Izabel Fernanda
Technical Paper
Laser Welding Applied to Complex Phase Steel2024-36-015912/20/2024
The development of advanced high-strength steels has become essential in the production of lightweight, safe, and more economical vehicles within the context of the automotive industry. Among the advanced high-strength steels, complex phase steels stand out, characterized by their high formability and high energy absorption and deformation capacity. Laser welding is a technique that applies laser using high energy density as a heat source. It has the advantages that the high welding speed and low heat input compared to other welding methods cause a decrease in deformation, and the narrow width of the weld bead and heat-affected zone allows for the welding of complex parts that would be difficult for other welding methods. Based on a study of a complex phase steel, an analysis was made of the microstructures observed by optical microscopy, the grain boundaries and certain phases contained in this microstructure, as well as the microstructures of each area in the laser welding region
Dias, Erica Ximenes, Reis de Faria Neto, Antonio, Castro, Thais Santos, Martins, Marcelo Sampaio, Santos Pereira, Marcelo
Technical Paper
INSERT, SCREW THREAD, NON-LOCKING, LOCKED IN, KEY LOCKED, HEAVY-DUTY, SELF-BROACHING KEYS, UNS S66286AS3572B (Current)12/18/2024
E-25 General Standards for Aerospace and Propulsion Systems
Technical Standard
Steel Bars, Forgings, Tubing, and Forging Stock 1.0Cr - 3.25Ni - 0.40Mo (0.17 - 0.22C) Electroslag Remelted or Consumable Electrode Vacuum Remelted Premium Aircraft QualityAMS6493C (Current)12/18/2024
This specification covers a premium aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock.
AMS E Carbon and Low Alloy Steels Committee
Material Specification
Steel, Sheet, Strip, and Plate 0.95Cr - 0.20Mo (0.28 - 0.33C) (SAE 4130) Aircraft Quality, SpheroidizedAMS6351M (Current)12/18/2024
This specification covers an aircraft-quality, low-alloy steel in the form of sheet, strip, and plate.
AMS E Carbon and Low Alloy Steels Committee
Material Specification
Steel Sheet, Strip, and Plate 0.95Cr - 0.20Mo (0.28 - 0.33C) (SAE 4130) Aircraft QualityAMS6350R (Current)12/18/2024
This specification covers an aircraft-quality, low-alloy steel in the form of sheet, strip, and plate.
AMS E Carbon and Low Alloy Steels Committee
Material Specification
Steel, Bars, and Forgings, Aircraft Quality, 0.50Cr - 0.55Ni - 0.25Mo (0.38 - 0.43C) (SAE 8740) Heat Treated, 105 ksi (724 MPa) Tensile StrengthAMS6325M (Current)12/18/2024
This specification covers an aircraft-quality, low-alloy steel in the form of heat-treated bars and forgings.
AMS E Carbon and Low Alloy Steels Committee
Material Specification
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