Browse Topic: Ferrous metals

Items (13,026)

A New Test Rig for Electrically Actuated Landing Gear and Brake of a Small Transport Aircraft

2025-01-0161To be published on 05/02/2025

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, Bertolino, Antonio, Jacazio, Giovanni

Drilling Methods for Controlling Exit Burr Height in CRES Material Stacks

2025-01-0169To be published on 05/02/2025

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

INSTALLING AND REMOVAL TOOLS, CONNECTOR ELECTRICAL CONTACT, TYPE I, CLASS 1, COMPOSITION C

AS81969/17A (Current)04/02/2025

AE-8C2 Terminating Devices and Tooling Committee

Application of 1.7GPa Martensitic Steel in Dash Lower Cross Member to Enhance Automotive Frontal Impact Safety

2025-01-8218

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

Self-Piercing Riveting (SPR) of Magnesium High Pressure Die Casting and Dissimilar Materials

2025-01-8231

04/01/2025

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, Yousef, Wang, Gerry, Weiler, Jonathan

Research on Material Stress Strain Curve Prediction Methods Based on Transfer Learning and Artificial Intelligence

2025-01-8317

04/01/2025

The mechanical properties of materials play a crucial role in real life. However, methods to measure these properties are usually time-consuming and labour intensive. Small Punch Through (SPT) has non-destructive characteristics and can obtain load-displacement curves of specimens, but it cannot visually extract the mechanical properties of materials. Therefore, we designed a proprietary SPT experiment and fixture, built a finite element method (FEM) model and developed a multi-fidelity model capable of predicting the mechanical properties of steel and aluminium alloys. It makes use of multi-fidelity datasets obtained from SPT and FEM simulation experiments, and this integration allows us to support and optimize the predictive accuracy of the study, thus ensuring a comprehensive and reliable characterization of the mechanical properties of the materials. The model also takes into account variations in material thickness and can effectively predict the mechanical properties of materials

Zou, Jie, Chen, Yechao, Li, Shanshan, Huayang, Xiang

Thermomechanical Fatigue Behavior of Gray Cast Iron in Brake Rotors

2025-01-8319

04/01/2025

Gray cast iron is a cost-effective engineering material widely used for heavy duty engine blocks and brake rotor discs in vehicles. Thermomechanical fatigue (TMF) frequently occurs during vehicle operation due to temperature fluctuations in brake rotors. To speed up the design of the component, design structurally sounding brake rotors, and prevent premature thermally induced cracking, it is critical to investigate TMF behavior of the gray cast iron. This study presents a series of fatigue tests, including isothermal low cycle fatigue (LCF) tests at temperatures up to 700°C, as well as in-phase (IP) and out-of-phase (OP) TMF tests across various temperature ranges. 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 to enable simulation of thermally induced cracks in rotors.

Liu, Yi, Lee, Heewook, Hess, Devin, Coryell, Jason

Material-Combined Vehicle Brake Disc Design for Enhanced Cooling Performance

2025-01-8189

04/01/2025

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, Jiarui, Jia, Qing, Zhao, Wentao, Xia, Chao, Yang, Zhigang

Material Characterization of Newly-Developed Advanced High Strength Steels for Prediction of Crash Performance

2025-01-8220

04/01/2025

New highly ductile advanced high strength steel (AHSS) grades with tensile strength greater than 980 MPa have been developed with the aim of achieving a combination of high strength and excellent formability. The new jetQTM-Family [1, 2] offers high local and global ductility, which is expected to contribute to the improvement of vehicle crash performance. For the reliable design and management of vehicle crash performance, material modeling, including work hardening behavior 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 980jetQTM, 1180jetQTM, and conventional Dual-Phase (DP) steels are investigated through simple tensile and V-bending fracture tests incorporating experimental-numerical hybrid ductile fracture analysis. Based on the experimental results, the ductile fracture parameters in the Hosford

Sato, Kentaro, Sakaidani, Tomohiro, Ohnishi, Yoichiro, Paton, Adrian, Roesen, Hartwig

Elevated Fracture Resistance of Q&P1180 Steel after Forming and Paint-Baking

2025-01-8221

04/01/2025

According to several precedent studies, most of the cold-forming advanced high-strength steel (AHSS) grades can obtain reinforced yield strength from the automotive forming and paint-baking treatments without losing their fracture resistance like some aluminum alloys. Concisely, the mechanism of such behavior can be mainly attributed to the ‘Cottrell Atmospheres,’ some thermally mobilized interstitial atoms that cluster around and impede mobile dislocations during only the yielding stage of the plastic deformation but cannot continue durably enough to affect the fracture. Nevertheless, an exception, Q&P1180, was discovered from precedent studies and characterized in this work. Different from other AHSSs, this grade exhibited distinctively elevated fracture resistance and yield strength after the pre-straining and baking. Such uniqueness was speculated to be caused by 1) no soft ferrite in the microstructure and 2) the transformed fresh martensite induced by the plastic deformation

Hu, Jun, Sun, Yeting, Thomas, Grant

A New Methodology to Characterize the Influence of Paint Baking and Pre-Straining on the Tensile Properties of Third Generation Advanced High Strength Steels

2025-01-8223

04/01/2025

The current ASTM A653 standard for determining the bake hardening index (BHI) of sheet metals can lead to premature fracture at the transition radius of the tensile specimen in high strength steel grades. In this study, a new test procedure to characterize the BHI was developed and applied to 980 and 1180 MPa third generation advanced high strength steels (3G-AHSS). The so-called KS-1B methodology involves pre-straining over-sized tensile specimens followed by the extraction of an ASTM E8 sample, paint baking and re-testing to determine the BHI. Various pre-strain levels in the range of 2 to 10% were considered to evaluate the KS-1B procedure with select comparisons with the ASTM A653 methodology for pre-strain levels of 2 and 8%. Finally, to characterize the influence of paint baking at large strain levels, sheared edge conical hole expansion tests were conducted. The tensile mechanical properties of the 3G steels after paint baking were observed to be sensitive to the pre-strain with

Northcote, Rhys, Berry, Avalon, Narayanan, Advaith, Tolton, Cameron, Lee, Haea, Smith, Jonathan, McCarty, Eric, Butcher, Cliff

A New Inverse Method for the Determination of Mechanical Properties of an Angle-Ply Composite Laminate by the CLPT

2025-01-8323

04/01/2025

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, Sushree, Deb, Anindya

Establishment of Failure Simulation Models for Bonding of Carbon Fiber Laminated Skins and Cores in Monocoque Structures Based on Formula Student Racing Cars

2025-01-8006

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. In recent years, 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, significant stress at the adhesive layer between the skin and the core material at both ends of the laminate, often lead 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 Spreadsheet. Therefore, it is necessary to consider the influence of the bonding factor of toughened epoxy prepreg film on the mechanical properties of the laminated plate. This

Ning, Zicheng

Predicting Forming Limit of Hot Stamping Boron Steel Using a Modified Zener-Hollomon Parameter based Ductile Failure Criterion

2025-01-8225

04/01/2025

Combined with a modified Zener-Hollmon parameter, a recently proposed ductile failure criterion is further improved to predict the forming limit of boron steel at hot stamping temperatures. The ductile failure criterion takes into account the critical damage at localized necking or at fracture as a function of strain path and initial sheet thickness. The modified Zener-Hollomon parameter accounts for both effect of varying strain rate and temperature for Boron steel. Working FEM simulation, the capability of the ductile failure criterion is further demonstrated by predicting forming limit of a boron steel in an isothermal Nakajima dome test. Comparison shows the prediction matches quite well with the measurement.

Sheng, ZiQiang, Mallick, Pankaj

Understanding Forming Characteristics of Different Microstructure Steels within 980MPa and 1180MPa

2025-01-8222

04/01/2025

For electrical vehicle (EV) automotive body-in-white (BIW) structures, protection of passengers and battery in crash event becomes equally important. In addition to energy absorption, intrusion protection for battery and vehicle becomes extremely important and GPa advanced high strength steels (AHSS) including press hardened steels (PHS), DP/MP/CP/GEN3 steels have become material of choice for design for those components. Higher yield strength materials especially in 980/1180MPa MP and CP category are chosen for part design over conventional low yield strength DP. In this study, the forming characteristics including both global and local formability are evaluated and compared among 980 DP/MP grades. Formability test such as forming limit curve (FLC), true fracture strain, V bend, half dome, and hole expansion tests are conducted. Microstructure analysis to understand the effect of different grain structure and phases of DP/MP grades is also accomplished. A T-shape laboratory die trials

Shih, Hua-Chu, Pednekar, Vasant, Shi, Ming, Singh, Jatinder, Tedesco, Sarah, Wu, Wei

Fatigue Strength of Gray Cast Iron – New Insights Regarding the Size Effects

2025-01-8238

04/01/2025

Gray 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 its good characteristics, in relation to lubrication, heat conductivity and damping. Engine parts particularly 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 of the cyclic material behavior of GJL materials. Within a comprehensive study, different GJL materials have been investigated at Fraunhofer LBF to provide more detailed information regarding the influence of size effects on fatigue strength. Accordingly, a variety of specimen

Bleicher, Christoph, Kansy, Axel

Machine Learning–Based Modeling for Predicting the Lap Shear Strength of High-Strength Steel Laser Lap Welds

05-18-04-0029

03/29/2025

This study investigates the nonlinear correlation between laser welding parameters and weld quality, employing machine learning techniques to enhance the predictive accuracy of tensile lap shear strength (TLS) in automotive QP1180 high-strength steel joints. By incorporating three algorithms: random forest (RF), backpropagation neural network (BPNN), and K-nearest neighbors regression (KNN), with Bayesian optimization (BO), an efficient predictive model has been developed. The results demonstrated that the RF model optimized by the BO algorithm performed best in predicting the strength of high-strength steel plate-welded joints, with an R 2 of 0.961. Furthermore, the trained RF model was applied to identify the parameter combination for the maximum TLS value within the selected parameter range through grid search, and its effectiveness was experimentally verified. The model predictions were accurate, with errors controlled within 6.73%. The TLS obtained from the reverse-selected

Han, Jinbang, Ji, Yuxiang, Liu, Yong, Liu, Zhao, Wang, Xianhui, Han, Weijian, Wu, Kun

BOLT, TEE HEAD, CHAMFERED - CRES, UNS S66286, 130 KSI MIN, .1900-32 UNJF-3A

AS9432C (Current)

03/25/2025

E-25 General Standards for Aerospace and Propulsion Systems

Steel Tubing, Seamless 0.15 Carbon Maximum (SAE 1010) Annealed

AMS5050M (Historical)

03/25/2025

This specification covers a low-carbon steel in the form of seamless tubing up to 5.50 inches (139.7 mm), nominal OD, inclusive.

AMS E Carbon and Low Alloy Steels Committee

BOLT, TEE HEAD, CHAMFERED - CRES, UNS S66286, 130 KSI MIN, .2500-28 UNJF-3A

AS9433C (Current)

03/25/2025

E-25 General Standards for Aerospace and Propulsion Systems

Classification of Common Imperfections in Sheet Steel

J810_202503 (Current)

03/25/2025

Common or obvious surface imperfections are normally visible to the naked eye before or after fabrication or processing. Illustrations and definitions of these imperfections are contained in this SAE Information Report. The identifying names are those commonly used throughout the steel industry. The imperfections identified include the major and most often encountered imperfections known to exist at this time. These imperfections are variable in appearance and severity. Extreme conditions have been selected in some instances in order to obtain suitable photographs. Photographs are courtesy of the American Iron and Steel Institute, Kaiser Aluminum, U.S. Steel, Nucor Steel, Samuel Steel, Steel Dynamics, Worthington Steel, and companies no longer in existence: LTV Steel, National Steel, and The Budd Company.

Metals Technical Committee

Steel, Corrosion- and Heat-Resistant, Welding Wire 15Cr - 25.5Ni - 1.3Mo - 2.2Ti - 0.006B - 0.30V (A286)

AMS5804J (Current)

03/25/2025

This specification covers a corrosion- and heat-resistant steel in the form of welding wire.

AMS F Corrosion and Heat Resistant Alloys Committee

INSERT, SCREW THREAD, HELICAL COIL, METRIC SERIES, SCREW LOCKING, CRES, CADMIUM PLATED

MA3331E (Current)

03/25/2025

E-25 General Standards for Aerospace and Propulsion Systems

Steel, Corrosion- and Heat-Resistant, Bars, Wire, Forgings and Forging Stock 18Cr - 10.5Ni - 0.60Cb (347F, 347FSe) Free-Machining, Solution Heat Treated

AMS5642N (Current)

03/25/2025

This specification covers two types of free-machining, corrosion- and heat-resistant steel in the form of bars, wire, forgings, and forging stock.

AMS F Corrosion and Heat Resistant Alloys Committee

INSERT, SCREW THREAD, HELICAL COIL, METRIC SERIES, SCREW LOCKING, CRES, DRY FILM LUBRICATED

MA3330E (Current)

03/25/2025

E-25 General Standards for Aerospace and Propulsion Systems

BOLT, TEE HEAD, CHAMFERED - CRES, UNS S66286, 130 KSI MIN, .3125-24 UNJF-3A

AS9434C (Current)

03/25/2025

E-25 General Standards for Aerospace and Propulsion Systems

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

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 Remelted

AMS5622/H1025A (Current)02/25/2025

AMS F Corrosion and Heat Resistant Alloys Committee

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

AMS F Corrosion and Heat Resistant Alloys Committee

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

AMS F Corrosion and Heat Resistant Alloys Committee

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, Annealed

AMS5900D (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

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

AMS F Corrosion and Heat Resistant Alloys Committee

Steel, Sheet, Strip, and Plate 0.80Cr - 1.8Ni - 0.25Mo (0.38 - 0.43C) (SAE 4340). Aircraft Quality

AMS6359M (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

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

AMS F Corrosion and Heat Resistant Alloys Committee

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

Multi-Objective Optimization of Powder-Mixed Electro-Discharge Machining of Tool Steel Using Advanced Algorithm

05-18-03-0021

02/20/2025

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

TOC

99-07-01-0TOC

02/17/2025

TOC

Tobolski, Sue

Evaluation on Mechanical and Metallurgical Properties of Wire Arc Additive Manufactured ER 2209 Duplex Stainless Steel for Automotive and Marine Applications

2025-28-0108

02/07/2025

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

Effect of Hardening and Tempering Temperatures on the Mechanical Behavior of Alloy Steel

2025-28-0027

02/07/2025

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

Crash Performance Study on High-Speed Electric Two-Wheeler Battery Enclosure

2025-28-0203

02/07/2025

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

Optimization of Wire Electrical Discharge Machining Parameters for Invar 36 Material Using Regression Modeling

2025-28-0122

02/07/2025

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

Steel Sheet, Strip, and Plate 0.95Cr - 0.20Mo - (0.38 - 0.43C) (SAE 4140) Aircraft Quality

AMS6395K (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

Design and Optimization of Low-Budget Yokeless and Segmented Armature Electrical Machine

2025-01-7055

01/31/2025

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

Microstructure and Strength of Zinc-Molybdenum Steel Joints Brazed with Nickel-Chromium-Zinc Filler Metal

2024-01-5255

01/28/2025

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.

Advancements in Lightweight Composite Materials for Enhancing the Structural Integrity of Automotive Component

2025-01-5005

01/23/2025

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.

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

Steel, Corrosion Resistant, Sheet, Strip, and Plate 18Cr - 8.5Ni (302) Solution Heat Treated, High Ductility

AMS5515P (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

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 Quality

AMS6385M (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

Investigating the Orientation-Dependent Mechanical Properties and Microstructure of 304L Austenitic Stainless Steel Fabricated via Wire Arc Additive Manufacturing

2025-01-5001

01/15/2025

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.

Laser Welding Applied to Complex Phase Steel

2024-36-0159

12/20/2024

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

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