Browse Topic: Ferrous metals

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Optimizing joint efficiency in stainless steel-aluminum alloy FSW joints through advanced parameter control2026-01-0228To be published on 04/07/2026
The present work investigates the friction stir welding (FSW) of dissimilar materials, specifically stainless steel 304 and aluminum alloy AA2024-T3, to analyze their tensile strength behavior. The significant challenges inherent in joining these materials, stemming from their vastly divergent thermal and mechanical properties, are addressed through a structured experimental and statistical methodology. The L18 Taguchi mixed orthogonal array was employed to systematically evaluate the influence of three critical process parameters: tool rotational speed, welding speed, and tool pin offset. Eighteen experimental trials were conducted using a butt joint configuration. The analysis identified tool rotational speed as the most influential parameter affecting the joint integrity. A combination of 450 rpm rotational speed, 20 mm/min welding speed, and a 1.5 mm pin offset toward the aluminum side yielded the optimum results, achieving a peak ultimate tensile strength (UTS) of 344.7 MPa and a
Mir, Fayaz Ahmad, Khan, Noor Zaman, Pali, Harveer Singh
Multi-material topology optimization using difference-based equivalent static load method2026-01-0173To be published on 04/07/2026
Topology optimization (TO) has become a powerful tool for generating lightweight structural designs. TO has been widely applied to linear static problems, where analytical sensitivities are easy to obtain. However, crashworthiness design requires nonlinear dynamic analysis, for which analytical sensitivities are generally not available. To extend TO into crash problems, approximation methods such as the Equivalent Static Load (ESL) method have been developed. ESL replaces the nonlinear problem with a series of linear static subproblems, ensuring that the displacement fields match at certain time steps. These subproblems can then be efficiently solved using standard TO techniques. A key limitation of ESL is that it relies on the initial mesh for all subproblems, which reduces accuracy for highly nonlinear crash responses. To address this, Triller proposed the difference-based ESL (DiESL) method, which updates the mesh in each subproblem to the deformed configuration, therefore improving
Huang, Yuhao, Kim, Il Yong
Tensile and Fatigue Behavior of High Pressure Die Cast AE44 Magnesium Alloy at Elevated Temperatures2026-01-0234To be published on 04/07/2026
Tensile and cyclic behavior of high pressure die cast AE44 magnesium alloy have been studied at room temperature and elevated temperatures up to 350°C. Anelastic behavior has been found in both tensile and cyclic deformation at the temperature below 150°C. With increasing temperature, the anelasticity disappears, and tensile and cyclic behaviors become similar to other engineering materials, such as steels and aluminum alloys, i.e. the total strain contains only elastic strain and plastic strain. A method to determine the yield strength at 0.2% plastic strain (σ0.2) is proposed. By using the proposed method, the yield strength σ0.2 is higher than that determined using the traditional method, which is more suitable to the materials that do not exhibit anelasticity. It is believed that the anelasticity is closely related to twinning in Mg alloy, which disappears at elevated temperatures.
Liu, Yi, Yang, Wenying, Coryell, Jason
Effective Prediction of the Mechanical Properties of Glue-Laminated Motor Core with consideration of glue disposition and stacking factor.2026-01-0177To be published on 04/07/2026
This study presents a practical approach for predicting the mechanical properties of glue-laminated motor cores, with a particular focus on the influence of glue disposition patterns and coverage rate, to enable more accurate material modeling and reliable NVH and other general structural analysis. Since glue bonding and lamination stacking are essential for ensuring the structural integrity of motor stator cores, variations in glue implementation introduce significant changes in both in-plane and out-of-plane stiffness properties. To address this, a homogenization framework based on the unit-cell method, considering detailed glue application information, is employed. The laminated structure is idealized as an orthotropic material, and the variation of in-plane properties in different directions is considered. Unlike simplified coverage-rate models, the proposed method incorporates localized glue distribution patterns—such as teeth, core back iron, and edge-concentrated regions like
Nie, Zifeng
Predicting Tensile Properties of Cast Stainless Steels via Machine Learning2026-01-0237To be published on 04/07/2026
In the category of cast stainless steels, there are several variants per different level of addition of chromium (Cr), vanadium (V) along with some minor elements, such as molybdenum (Mo), niobium (Nb), tungsten (W) to meet the requirement of corrosion and oxidation resistance. However, the influence of chemical composition variations on the mechanical properties of cast SS continues to lack a clear understanding. In the present study, via machine learning (ML), the effects of each element on the tensile properties of the cast stainless steel are studied. The ML model is then used to predict how variations in elements affect tensile behavior, with the predictions validated through physical testing.
Mishra, Neelam, Biswas, Surjayan, V S, Rajamanickam, Aluru, Phani, Liu, Yi, Akbari, Meysam, Coryell, Jason
Wear and Friction of PTFE and PEEK Coated Cast Iron for Piston Ring Application2026-01-0240To be published on 04/07/2026
In engine 30% of the total energy is lost due to the friction between piston ring and cylinder liner due to their constant rubbing motion. A piston that reciprocates at high speeds has piston rings that constantly scrape against the wall leading to high frictional losses within the engine. The engine has to work against this resistance to provide the required power, and hence it will consume more fuel. For this reason, material used for these components is more crucial. Reduction of surface friction between moving parts in order to increase overall efficiency can be achieved by suitable coating. The most commonly used piston rings are coated with chromium layers that are electroplated which is being replaced by chrome plating. Low coefficient of friction (COF) and high wear resistance can be achieved by self-lubricating coating of PTFE and PEEK polymer-based composite coatings. Experimental results showed that the PEEK and PTFE coating performed better in terms of friction and wear
Rajendran, R., Tamilarasan, T R, J, Chandradass
Comparison of Formability Performance Between CR550LA and CR590DP2026-01-0178To be published on 04/07/2026
While rapid development of advanced high strength steels (AHSS) for a safer and lighter vehicle has been a primary focus in the automotive industry, the application of traditional high strength low alloy (HSLA) steel continues to be actively supported and developed. AHSS are often used to replace HSLA steels for downgauging while maintaining similar or better performance in crashworthiness and durability. However, recent developments have enabled the availability of higher strength, cold-rolled HSLA steels that could offer opportunities for a more balanced solution between material cost and material performance. Certain higher strength HSLA steels not only offer a cost-effective way to increase the strength-to-weight ratio but also provide comparable formability and better weldability to AHSS. In this study, cold rolled HSLA grades of CR340LA, CR420LA, and CR550LA are evaluated in overall formability and in-use performance when compared to CR590 dual phase (DP) grade. The evaluations
Shih, Hua-Chu, Brown, Lindsay, Pednekar, Vasant, Shi, Ming, Tedesco, Sarah
Steel Bars, Forgings, Mechanical Tubing and Forging Stock, Nitriding, 1.4Cr - 1.2Mo - 0.3V (0.29 - 0.36C) (32CrMoNiV5), Aircraft-Quality for Bearing ApplicationsAMS6496C (Current)3/12/2026
This specification covers a nitriding grade of aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock. AMS6497 and AMS6498 cover UNS K23280 having other quality levels.
AMS E Carbon and Low Alloy Steels Committee
Steel Cleanliness, Special Aircraft-Quality, Magnetic Particle Inspection ProcedureAMS2304D (Current)3/12/2026
This specification covers steel cleanliness requirements for special aircraft-quality ferromagnetic steels, including hardenable corrosion-resistant steels, by magnetic particle inspection methods. This specification contains sampling, sample preparation, inspection procedures, and cleanliness rating criteria (see 8.2).
AMS E Carbon and Low Alloy Steels Committee
Steel Cleanliness, Aircraft-Quality, Magnetic Particle Inspection ProcedureAMS2301M (Current)3/12/2026
This specification covers steel cleanliness requirements for aircraft-quality ferromagnetic steels, other than hardenable corrosion-resistant steels (refer to AMS2303), by magnetic particle inspection methods. This specification contains sampling, specimen preparation, inspection procedures, and cleanliness rating criteria (see 8.2).
AMS E Carbon and Low Alloy Steels Committee
Steel, Welding Wire, 0.50Cr - 0.55Ni - 0.20Mo (0.18 - 0.23C) (SAE 8620), Vacuum Melted, Environment Controlled PackagingAMS6375F (Current)3/4/2026
This specification covers a low-alloy steel in the form of welding wire. Type 2 - copper coated wire was removed from this document (see 8.4).
AMS E Carbon and Low Alloy Steels Committee
Steel Tubing, Seamless, 0.95Cr - 0.20Mo (0.33 - 0.38C) (4135), Aircraft-Quality, Normalized and Tempered or Stress RelievedAMS6365M (Current)3/4/2026
This specification covers an aircraft-quality, low-alloy steel in the form of seamless tubing.
AMS E Carbon and Low Alloy Steels Committee
Rings, Piston, Cast Iron As CastAMS7310M (Current)3/3/2026
This specification covers piston rings fabricated from cast iron.
AMS E Carbon and Low Alloy Steels Committee
Failure Cause Analysis of Valve-Regulated Lead-Acid Battery on Fire in Communication Equipment Room2026-01-70222/27/2026
This paper carried out the fire failure analysis of valve-regulated lead-acid battery in communication equipment room. Through disassembly and observation of the battery and iron frame of battery cabinet in the area of fire origin, we obtained the key residual traces and used the physical and chemical analysis methods such as macroscopic/microscopic morphology, EDS, X-ray and metallographic, it was finally judged that the leakage of the battery electrolyte lead to the connection of the battery electrode plate and the iron frame and subsequently the electric heating fault caused the fire accident. Furthermore, we put forward some suggestions according to the existing problems, which may contribute to the prevention of similar failures.
Guo, Yuhang
Experimental Vibroacoustic Measurement of Thin Steel Panels Coated with Different Liquid-Applied Spray Damping Layer Thickness10-10-02-00172/23/2026
This study investigates the effect of liquid-applied spray damping (LASD) thickness on the vibration and sound radiation of thin steel panels. Although LASD is widely used to enhance structural damping, its influence on radiated sound and the role of coating thickness have not been systematically studied. Five steel panels with varying LASD thicknesses were evaluated using two experimental approaches. An impact-based method in a hemi-anechoic chamber measured the structural mobility and noise transfer functions, while a reciprocal method in a reverberation chamber under acoustic excitation measured the radiated sound power transfer function. A thickness ratio was found beyond which additional LASD thickness yielded diminishing improvements in noise and vibration reductions. The effect of LASD thickness on radiation efficiency was also assessed in both narrowband and one-third octave bands.
Neihguk, David, Suh, Sam, Herrin, David W.
Blackening Solution for Steel Touch-Up MethodAMS2484D (Current)2/16/2026
This specification covers the requirements for an inorganic blackening solution for steel, applied at room temperature.
AMS B Finishes Processes and Fluids Committee
Evolution of a Novel Hybrid Stab-Link for a Born Electric Sports Utility Vehicle2026-28-00012/12/2026
The present study details the design evolution and failure analysis of a novel hybrid stabilizer bar link (stab link) developed for the front suspension of a born electric sports utility vehicle (SUV) platform characterized by higher gross vehicle weight (GVW), increased wheel travel, and constrained packaging space. To address these challenges, a unique hybrid stab link was designed featuring dual plastic housings at both the metal ball joint ends, connected by a steel tube, and achieving a 30% weight reduction while offering enhanced articulation angles for extremely lower turning circle diameter (TCD) of the vehicle, compared to the conventional stab link. The unique hybrid stab failed under complex loading conditions during accelerated durability testing (ADT), prompting a comprehensive investigation. The failure analysis included road load data acquisition across various stab bar diameter configurations evolved during suspension tuning, different stabilizer link designs evolved
Selvendiran, P, J, Ramkumar, Nayak, Bhargav, M, Sudhan, Patnala, Avinash
Effect of Sebastiana Rostrata Fiber Loading on the Tribological Behaviour of Polycaprolactone Biocomposite2026-28-00212/12/2026
This study investigates the tribological behaviour of Sesbania rostrata fiber (SRF) reinforced polycaprolactone (PCL) biocomposites using a pin-on-disc wear couple. The stationary SRF/PCL composite specimen interacted with a rotating EN31 steel disc (64 HRC), establishing the sliding wear interface in accordance with ASTM G99 standards. Composite laminates containing 10, 20, and 30 wt% SRF were evaluated at a sliding velocity of 1 m/s over a fixed distance of 1000 m under varying normal loads. The incorporation of SRF significantly enhanced the wear performance relative to neat PCL, with 20 wt% fiber loading achieving the lowest coefficient of friction and specific wear rate due to improved load transfer, stronger interfacial adhesion, and a more uniform laminate structure. In contrast, the 30 wt% composite exhibited fiber agglomeration, reduced homogeneity, and weakened fiber–matrix interactions, resulting in increased wear. SEM microstructural analysis confirmed the formation of a
Raja, K., Senthil Kumar, M.S.
Modelling and Analysis of Complex Shaped Cracks2026-28-00482/12/2026
This study provides an extensive analysis through finite element analysis (FEA) on the effects of fatigue crack growth in three different materials: Structural steel, Titanium alloy (Ti Grade 2), and printed circuit board (PCB) laminates based on epoxy/aramid. A simulation of the materials was created using ANSYS Workbench with static and cyclic loading to examine how the materials were expected to fail. The method was based on LEFM and made use of the Maximum Circumferential Stress Criterion to predict where cracks would happen and how they would progress. Normalizing SIFs while a crack was under mixed loading conditions was achieved using the EDI method [84]. We used Paris Law to model fatigue crack growth using constants (C and m) for the materials from previous studies and/or tests. For example, in the case of titanium Grade 2, we found Paris Law constants with C values from 1.8 × 10-10 to 7.9 × 10-12 m/cycle and m values from 2.4 to 4.3, which illustrate differing effects of their
T, Lokesh, Bhaskara Rao, Lokavarapu
Steel, Corrosion-Resistant, Sheet, Strip, and Plate, 15Cr - 4.5Ni - 0.30Cb (Nb) - 3.5Cu (15-5PH®), Consumable Electrode Remelted, Premium Aircraft Quality, Solution Heat Treated and Precipitation Hardened (H1025)AMS5862/H1025 (Current)2/11/2026
This specification covers a corrosion-resistant steel product in the solution and precipitation heat-treated (H1025) condition, 4 inches (102 mm) and under in nominal thickness.
AMS F Corrosion and Heat Resistant Alloys Committee
Steel, Corrosion- and Heat-Resistant, Welding Wire, 16.5Cr - 4.5Ni - 2.9Mo - 0.10N (AM350)AMS5774F (Current)2/1/2026
This specification covers a corrosion- and heat-resistant steel in the form of welding wire.
AMS F Corrosion and Heat Resistant Alloys Committee
Quality Assurance Sampling and Testing, Carbon and Low-Alloy Steel ForgingsAMS2372J (Current)2/1/2026
This specification covers quality assurance sampling and testing procedures used to determine conformance to applicable specification requirements of carbon and low-alloy steel forgings.
AMS E Carbon and Low Alloy Steels Committee
Steel, Corrosion-Resistant, Bars, Wire, Forgings, Mechanical Tubing and Forging Stock, 16Cr - 2.5Ni (SAE 51431), Aircraft QualityAMS5628G (Current)1/31/2026
This specification covers a heat-treatable, corrosion-resistant steel in the form of bars, wire, forgings, mechanical tubing, and stock for forging or heading.
AMS F Corrosion and Heat Resistant Alloys Committee
Steel, Corrosion-Resistant, Investment Castings, 16Cr - 4.1Ni - 0.28Cb (Nb) - 3.2Cu (17-4), Homogenization, Solution, and Precipitation Heat Treated (H1100), 130 ksi (896 MPa) Tensile StrengthAMS5342G (Current)1/27/2026
This specification covers a corrosion-resistant steel in the form of investment castings homogenized and solution and precipitation heat treated to 130 ksi (895 MPa) tensile strength.
AMS F Corrosion and Heat Resistant Alloys Committee
INSERT, SCREW THREAD, SHORT, SELF-LOCKING, KEY LOCKED, OVERSIZE SELF-BROACHING KEYS, UNS S66286AS3652A (Current)1/26/2026
E-25 General Standards for Aerospace and Propulsion Systems
Steel, Welding Wire, 0.65Si - 1.25Cr - 0.50Mo - 0.30V (0.28 - 0.33C) [17-22A(S)], Vacuum Melted, Environment Controlled PackagingAMS6458L (Current)1/23/2026
This specification covers a low-alloy steel in the form of bare welding wire. Type 2 - copper coated wire was removed from this document (see 8.4).
AMS E Carbon and Low Alloy Steels Committee
Steel, Corrosion-Resistant, Investment Castings, 16Cr - 4.1Ni - 0.28Cb - 3.2Cu, Homogenization, Solution, and Precipitation Heat Treated (H900), 180 ksi (1241 MPa) Tensile Strength (17-4)AMS5344H (Current)1/19/2026
This specification covers a corrosion-resistant steel in the form of investment castings homogenized and solution and precipitation heat treated to 180 ksi (1241 MPa) tensile strength.
AMS F Corrosion and Heat Resistant Alloys Committee
Niobium Alloyed Brake Disc for reduced NVH and Emission Control2026-26-02851/16/2026
Recent regulations limiting brake dust emissions have presented many challenges to the brake engineering community. The objective of this paper is to provide a low cost, mass production solution utilizing well known existing technologies to meet brake emissions requirements. The proposed process is to alloy the Gray Cast Iron with Niobium and subsequently Ferritic Nitrocarburize (FNC) the disc. The Niobium addition will improve the wear resistance of the FNC case, reducing wear debris. The test methodology included: 1. Manufacture of disc samples alloyed with Niobium, 2. Finish machining and ferritic nitrocarburizing and 3. Evaluation of airborne wear debris utilizing a pin-on-disc tribometer equipped with emission collection capability. The airborne emission and wear surfaces were further analyzed by Scanning Electron Microscopy, Energy Dispersive techniques (SEM-EDS), X-Ray Diffraction and Optical Microscopy. The cast iron test matrix included four groups; Unalloyed eutectic 4.3
Barile, Bernardo, Holly, Mike
Improvement Study of Style Steel Wheel Durability in Multiple Pothole Impacts2026-26-05391/16/2026
This study focuses on improving the durability of steel wheel rims subjected to Multiple Pothole which is commonly found in Indian village roads — a critical scenario affecting vehicle safety and wheel lifespan. Initial steel wheel designs often face significant deformation or failure under repeated strikes and resulting in tyre air loss due to wheel bend, prompting the need for enhanced performance standards. In this research, a combination of finite element modelling, experimental impact testing, and material optimization strategies were employed to assess and improve the structural integrity of steel rims. Key parameters such as rim profile geometry & material composition were systematically varied to evaluate their influence on impact resistance. Results demonstrate that strategic design modifications and material enhancements can significantly increase the rim's ability to absorb energy and resist bending without substantial weight penalties. The findings offer practical
DEsigan, Lakshmipathy, P, Praveen, K, Chandramohan, C, Santhosh
Design and Development of a Lightweight Aluminium Cascade System for Type IV COPVs for Stationary and Mobile Applications2026-26-04851/16/2026
The global push for clean energy has made hydrogen a central element in decarbonizing transport, industrial processes, and energy systems. Effective hydrogen storage and distribution are critical to supporting this transition, and type IV Composite Overwrapped Pressure Vessels (COPVs) have emerged as the preferred solution due to their lightweight, high pressure capacity, hydrogen embrittlement and corrosion resistance. However, the cascade infrastructure used to house and transport these vessels has lagged behind in innovation. Steel-based cascades, while strong, are heavy prone to corrosion, and unsuitable for mobile deployment. This paper introduces a custom designed aluminium cascade system offering a 65% weight reduction while maintaining structural integrity and safety. Designed for mobile use, the system features modularity, better damping, and enhanced corrosion protection. The paper outlines design methodology, material selection, fabrication process, and comparative
Parasumanna, Ajeet Babu, Muthusamy, Hariprasad, Ammu, Vnsu Viswanath, Kola, Immanuel Raju
Steel-Based Laminates for Lithium-ion Pouch Cell of Electric Vehicles2026-26-01861/16/2026
Aluminum foils have gained traction with EV battery manufacturers for their pouch cell format. Over the years, it has evolved as a material of choice, but it is still plagued by the issues of stress concentration and swelling due to lower strength and lower stiffness of base aluminum layer. Preliminary investigation revealed that laminates using steel foil material (thickness < 0.1mm) could be a potential candidate for EV pouch cell casing. Thus, steel-based laminate was developed meeting key functional requirements (e.g., barrier performance, insulation resistance, peel strength, electrolyte resistance, formable without cracking at edges, and heat sealing compliant). This innovative patented steel-based laminate [1] was further used to manufacture pouch cell prototypes (up to a maximum capacity of 2.8Ah) for key performance evaluation (e.g., cell cycling and nail penetration). The study paves the way for a low cost, sustainable and flexible yet strong steel-based laminate packaging
Singh, Pundan Kumar, Raj, Abhishek, Kumar, Ankit, Chatterjee, Sourabh, Verma, Rahul Kumar, Samantaray, Bikash, Gautam, Vikas, Pandey, Ashwani
Experimental Study on the Role of Hole Expansion Ratio in Enhancing Crashworthiness of Advanced High Strength Steel2026-26-02951/16/2026
To meet light weighting and safety targets, the automotive industry is increasingly using advanced high strength steel (AHSS) materials and advanced manufacturing techniques for complex body parts. To improve energy absorption of automotive body parts, various steel grades are developed by steel manufactures with variety of properties (YS, UTS, EL %, HER). Also, the formability of AHSS grades (TS > 980 MPa) is challenging due to its limited edge ductility. This study focuses on role of hole expansion ratio (HER) in energy absorption of AHSS material. In the study, different AHSS material with variety of microstructure and properties are experimented, with the aim to identify the optimum properties that can help to enhance crash worthiness of formed part. From experimentation, it is evident that hole expansion ratio plays an important role in determining edge ductility, as well as energy absorption. This study may not only help to improve crash performance but also help for light
Jain, Vikas, Bandru, Shreenu, Nadarge, Harshad, Misal, Swapnali, Deshmukh, Mansi, Paliwal, Lokesh
Assessing the Impact of Hole Piercing Edge Quality on Fatigue Samples for S550MC Steel Sheet2026-26-03061/16/2026
The exceptional strength, formability, and weldability of S550MC steel sheets make them a cornerstone material in the automotive industry. These properties translate into the creation of high-performance automotive components like chassis parts, structural reinforcements, ultimately contributing to enhanced vehicle safety and overall performance. Furthermore, S550MC steel boasts excellent fatigue resistance, a critical factor for ensuring long-term reliability in demanding automotive applications that experience repeated stress cycles. However, optimizing the performance of S550MC components depends on a fine understanding of the critical relationship between hole edge quality and fatigue failure. This study highlights the impact of hole-piercing clearance on the edge quality of the hole in modified fatigue samples manufactured from S550MC steel, and its effect on fatigue life. The surface morphology was characterized by using stereoscope for edge quality of hole piercing operation
Nahalde, Sujay, Hingalje, Abhijeet, Ughade, Vikas, Singh, Udita, More, Hemant
Non-Metallic Inclusions in Carburizing Steels as a Contributory Factor for the Formation of Carbide Net2026-26-02901/16/2026
The article deals with the issue of identifying structural defects that contribute to the formation of a carbide net during thermochemical treatment of steel parts, which negatively affects the mechanical properties complex of finished products. Based on the available data, a theory has been put forward regarding the influence of the present non-metallic inclusions in the carburizing steels structure on carbide formation process in the hardened layer. As an experimentally the samples have been produced from the varying chemical composition alloy structure carburized steel (0.17-0.23 % C, 0.17-0.37 % Si, 0.80-1.10 % Mn, 1.00-1.30 % Cr, 0.03-0.09 % Ti). During microstructure analysis of the samples it has been establish that non-metallic inclusions, in particular sulfides, contribute to the formation of carbides and carbide net in steel due to their high chemical activity with carbon. Thus, contamination of the metal of carburizing steels with non-metallic inclusions is not only a defect
Runova, Iuliia, Chatkina, Mariia, Musienko, Aleksandr
Evaluation of Shear Trim Edge in HSLA Steel for Automotive Application2026-26-02861/16/2026
Quality of the Shear Trimmed edge of HSLA 550 steels is significantly affected by process variations such as Shear Trimming Clearance, trim tolerance, burr height and clamping force. All these parameters largely influence the characteristics of the Shear Affected Zone, a region on sheet metal where it undergoes deformation during the trimming process. The Shear Affected Zone is predominantly vulnerable to failure due to work hardening and the effects of strain rate, induced by the tonnage during the trimming operation. To assess the edge ductility of these materials, Tensile, Fatigue Strength, Die Punch Clearance, Roughness and Hardness Tests are carried out. These tests are crucial for applications that demand high formability and resistance to edge failure. Virtual simulation of edge trimming operation using elastoplastic material models in LS-Dyna have been performed to gain insights into burr formation and damage evolution during shearing. These simulations act as a precursor to
Thota, Badri Vishal, Kashyap, Amit, Bhuvangiri, Jaydev
Experimental Evaluation of High Energy Impact Test of Wheel Rim2026-26-05041/16/2026
High energy impact testing using free fall mass is a crucial method for evaluating the structural integrity, and safety performance of automotive components subjected to sudden impact forces. This study focuses on assessing critical parts such as wheel rims, suspension knuckles, commonly exposed to unintentional impacts during vehicle operation, maintenance, or collisions. The test involves dropping a standardized mass from predetermined heights onto the component to simulate real-world impact scenarios. Key performance indicators include deformation, crack propagation, fracture resistance, and energy absorption capacity. Wheel rims and knuckles are evaluated for their ability to maintain structural integrity under localized impact without compromising vehicle handling or safety. Seats and related interior structures are tested to ensure occupant protection during crash-like events. Other components, such as brackets, mounts, or housings, are included based on functional criticality
Roham, Prasad, Bagade, Mohan, Sinnarkar, Nitin, Pawar, Prashant R, Shinde, Vikram
Optimization of Global and Local Formability Properties through Nb Microalloying2026-26-03031/16/2026
David Martin, CBMM Asia Bernardo Barile, CBMM Europe BV Caio Pisano, CBMM Europe BV Automotive high strength steels have specific microstructure-dependent forming characteristics. Global formability is generally associated with high uniform strain values which imply good drawability and stretch forming properties driven by pronounced work hardening. Local formability on the other hand is often measured by various fracture strain values—generally higher in single phase steels. In this respect, the so-called ‘local/global formability map’ concept has been established not only to provide a comprehensive methodology to characterize existing automotive steels but also to enable improvement strategies toward more balanced forming characteristics. Niobium (Nb) microalloying is a powerful tool to achieve both property improvement in general and property balance in particular. More than two decades of research has demonstrated that Nb-induced microstructural optimization is applicable to HSLA
Barile, Bernardo
Optimization of the Hood Ro-dip CED Process Through Strategic Support Rod Placement at Multiple Locations for Enhanced Hood Gap and Flushness Control in Automotive Manufacturing2026-26-04861/16/2026
The Ro-dip Cathodic Electrodeposition (CED) process is new technology used by automotive manufacturers for higher quality corrosion protection in new generation automobiles. This process involves multiple 360-degree rotation of automotive body-in-white (BIW) which exert higher hydrostatic pressure and drag forces on large surface panels of BIW like hood. For maintaining consistent gaps and flushness control at vehicle level, it is important to safeguard the dimensional stability of light weight (crash performance sensitive) steel hood panel while undergoing through this CED process. This study investigates the enhancement of hood structure supports through strategic optimization of support rod placement and quantity within the Ro-dip CED paint shop system. This Paper underscore the importance of tailored fixture design in the Ro-dip CED process, offering a scalable solution for automotive manufacturers aiming to improve quality while reducing costs associated with dimensional
Tile, Vikrant, Unadkat, Siddharth, Askari, Hasan, Jadhav, Devidas
Hydrogen Embrittlement in Galvanized High Carbon Steel Components of Automotive Seat Slider Assembly2026-26-03021/16/2026
This research paper investigates the failure of an isolator clip used in the seat slider assembly, which guides and restricts the sliding motion of the tooth bracket within the seat. The component is made of C80 high-carbon spring steel, known for its high strength. According to the manufacturing process details, zinc plating was applied to the component for corrosion protection, as confirmed by EDS analysis. A fractographic examination of the failed part revealed a brittle, intergranular fracture morphology with visible cracks. Certain areas also exhibited micro-void coalescence, indicating a dimpled fracture surface. The primary failure mode was intergranular (IG) fracture. The delayed fracture was attributed to intergranular fracture mechanisms, micro-void coalescence, and the high strength of the steel, which made the component susceptible to hydrogen embrittlement. Hydrogen embrittlement occurs when hydrogen atoms become trapped along the grain boundaries, where they form hydrogen
Saindane, Mehul Kishor, Bali, Shirish
Study on Seismic Performance of a Prefabricated CFST Bridge Pier2025-99-020412/23/2025
This paper investigates the seismic performance of the prefabricated concrete-filled steel tubular (CFST) bridge pier in the bridge system-level. The proposed prefabricated CFST bridge pier is composed of circular thin-walled CFST double-column, precast I-shaped tie beams, and precast RC cap beam, which are assembled by simply on-stie assembly connections, with advantages in good seismic performance, convenient construction, and comparable material cost. A total of 12 two-span continuous beam bridge cases are designed, including 2 typical bridges with reinforced concrete (RC) piers and 10 bridges with CFST piers. Numerical research on the hysteretic performance of piers in bridge cases, dynamic responses of all bridge cases, and their seismic fragility. The results demonstrate that prefabricated CFST piers outperform RC piers in both load-bearing capacity and energy dissipation, and these piers exhibit reduced transversal displacement at the top and decreased maximum curvature when
Gu, Chao, Wang, Xuanding
Study on Evolution of Surrounding Rock Stability and Structural Mechanical Behavior During In-Situ Expansion of Existing Tunnels in Weak Rock Mass2025-99-020712/23/2025
To address the escalating traffic demands and tackle the complex mechanical challenges inherent in in-situ tunnel expansion, this study, grounded in the Huangtuling Tunnel project in Zhejiang Province, China, focuses on the stability evolution of surrounding rock and the mechanical characteristics of structures during the in-situ expansion of existing tunnels under weak surrounding rock conditions. By systematically comparing core post-excavation features—such as surrounding rock displacement fields, ground pressure distribution pat-terns, and mechanical responses of support structures—between newly constructed tunnels and in-situ expanded tunnels, the research reveals key mechanical principles governing the construction of large-section tunnels in weak rock formations. Specifically, the findings are as follows: (1) Both newly constructed and in-situ expanded large-section tunnels exhibit significant spatial heterogeneity in surrounding rock deformation. The vault-spandrel zones serve
Zheng, Xiaoqing, Kang, Xiaoyue, Xu, Kai, Chen, Tao, Huo, Xinwang, Chen, Chuan
Calculation of Bending Capacity of L-Shaped Concrete Filled Steel Tube Special Column2025-99-021512/23/2025
In this paper, a systematic and in-depth study is carried out on the key engineering problem of the accurate calculation of the flexural capacity of L-shaped concrete-filled steel tubular columns. Based on the basic framework of mechanics theory, the basic design principle of reinforced concrete members is integrated, and the nonlinear characteristics of steel and concrete materials in the process of stress are mainly considered, such as steel yield strengthening, concrete compression damage, etc., and the ultimate bending moment calculation model which is more suitable for the actual stress state is constructed. Through rigorous theoretical derivation and multi-parameter comparative analysis, the final formula for calculating the bearing capacity of special-shaped columns not only has clear mechanical concept support, but also systematically defines the scope of application of the calculation method. The verification results show that the established calculation method not only meets
Wang, Cuicui, Bai, Shouyan, Wei, Hongxian, Lv, Shuang, Xu, Yafeng
Development of a Localized Heat Treatment Route for Stamped Automotive Parts2025-36-008912/18/2025
The increasing demand for sustainable and space-efficient manufacturing solutions in the automotive industry has driven the search for alternative processes to conventional hot stamping. This study proposes a novel localized heat treatment technique based on Joule heating, aiming to reduce the physical footprint of production equipment, simplify the thermal processing of structural components, and minimize the carbon footprint of the process. The method consists of cold stamping followed by localized austenitization of 22MnB5 steel using electrically powered copper electrodes, eliminating the need for large-scale gas-fired furnaces. The process is particularly advantageous in the Brazilian context, where the electric energy matrix is predominantly hydroelectric, contributing to lower CO2 emissions. Experimental trials were conducted using a Gleeble® thermomechanical simulator to optimize thermal cycle parameters (heating rate, austenitization temperature, and soaking time) ensuring the
Santana, Jessica, Curti, Gustavo, Lima, Tiago, Sarmento, Matheus, Callegari, Bruna, Folle, Luis
Influence of Microstructure on the Mechanical Properties of Laser-Welded Joints between Different Classes of Automotive Steels2025-36-004912/18/2025
The need to reduce vehicle weight without compromising safety drives the use of advanced high-strength steels (AHSS) in the automotive industry. Laser welding is a widely employed technique for joining dissimilar materials due to its high precision and small heat-affected zone (HAZ). However, differences in the chemical composition and thermomechanical properties of the materials can create heterogeneous microstructures in the fusion zone (FZ) and HAZ, directly impacting the mechanical properties of the welded joint. This study aims to evaluate the relationship between microstructure and mechanical properties in laser-welded joints of dissimilar automotive steels. The objective is to understand how microstructural transformations affect weld strength, ductility, and toughness, contributing to process parameter optimization and improved structural performance. Microstructural analysis will be performed using optical microscopy, and mechanical tests, such as tensile testing and
Santos, dos Flávio Nunes, Reis de Faria Neto, dos Antonio, Dias, Erica Ximenes, Martins, Marcelo Sampaio, Santos Pereira, dos Marcelo
Study on the Mechanical Properties of a High-Strength Aluminum Alloy Profiles2025-99-033212/17/2025
Compared to steel, aluminum alloy has the advantages of light weight, high specific strength, corrosion resistance, and easy processing, and is widely used in structures such as aviation, construction, bridges, and offshore oil platforms. All along, Chinese construction aluminum profiles have been produced according to the GB/T5237-XXXX standard, which is determined based on the mechanical performance requirements of doors and windows and the actual processing of aluminum profiles. There are many problems. The author of this article has developed a new product 6063-T56, which has a tensile strength of 240-260Mpa and an elongation rate of not less than 8%, surpassing the latest technology level in Europe. It has been promoted and applied to the aluminum profile production industry in China, improving product performance, reducing production costs, improving production efficiency, and meeting the requirements of the "Aluminum Alloy Doors and Windows Standard" GB/T8478-2020, making
Qiao, Zhou
Research on Invasion Line Control of Deep Foundation Pit Diaphragm Wall Excavation Based on Space-time Effect2025-99-031612/17/2025
The study focuses on the management of deep foundation pit excavation, influenced by temporal and spatial factors, in the context of the challenging environmental circumstances posed by the high-water-level silty soft clay along the Yellow River's northern shore, as part of the Jinan urban rail transit initiative. The subsequent inferences have been made: (1) Throughout the digging phase, issues such as excessive digging and delays in installing steel reinforcements occur, while the subterranean diaphragm wall tends to shift significantly inward within the excavation area due to the disparity in pressure between the water and soil inside and outside. (2) During the building phase, managing wall distortion is imperative, and an enhanced preliminary force should be applied to the support's axial component at points of significant deformation, guaranteeing an excess coefficient for both the support rigidity and the continuous subterranean wall rigidity. (3) In the process of diaphragm
Gao, Tiangang, Zhang, Xu, Pan, Fuyong, Zhang, Wenjun
Reliability Simulation Analysis of Low Nickel Stainless Steel Carbody Structure2025-99-032312/17/2025
The demand for lightweight and cost-effective materials in rail transportation is increasing. Low nickel nitrogen austenitic stainless steel is considered a promising alternative for stainless steel car body structures because of its excellent mechanical properties and corrosion resistance. Due to the complexity and large scale of such structures, the structural reliability of car bodies made from this material is regarded as a critical concern. This issue is also addressed in the present study. Finite element analysis (FEA) is employed using ABAQUS to evaluate the structural performance of a low nickel stainless steel car body under various operational conditions. Based on the material specifications outlined in GB/T 7928-2003 “Stainless Steel for Urban Rail Transit Vehicles,” the structural design requirements of EN 12663-2010 “Railway Applications - Structural Requirements of Railway Vehicle Bodies,” and the experimental requirements of TB/T 3502-2018 “Modal Test Method and
Jiang, Long, Xie, Kun, An, Ziliang, Zuo, Yiwen
Analysis of Stress Behavior at the Arch Foot of a Spatial Double-Arch Composite Steel Box Arch Bridge2025-99-034012/17/2025
To assess the structural response of the steel-concrete composite joint in a long-span half-through spatial double-arch steel box arch bridge throughout its construction and service life, a comprehensive analytical approach was implemented. Initially, a global beam-element model was constructed using Midas Civil software to determine the structural response during critical phases, including the primary construction stage (Stage 1) and operational conditions. Subsequently, a refined local finite element model focusing specifically on the arch foot's steel-concrete interface was developed in Ansys. The modeling methodology incorporated experimental validation through field instrumentation data, enabling detailed examination of both stress distribution patterns within the composite zone and the fundamental force transfer principles at this critical structural transition. Key findings from this investigation demonstrate: When subjected to the combined effects of permanent and transient
Dong, Huili
Steel, Bars, Forgings, Mechanical Tubing and Forging Stock, 0.50Cr - 0.55Ni - 0.20Mo (0.18 - 0.23C) (SAE 8620), Premium Aircraft Quality, Consumable Electrode Vacuum RemeltedAMS6276N (Current)12/16/2025
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
Seamless Low-Carbon Steel Tubing Annealed for Bending and FlaringJ524_202512 (Current)12/11/2025
This SAE Standard covers cold drawn and annealed seamless low-carbon steel pressure tubing intended for use as hydraulic lines and in other applications requiring tubing of a quality suitable for flaring and bending. In an effort to standardize within a global marketplace and ensuring that companies can remain competitive in an international market it is the intent to convert to metric tube sizes which will: Lead to one global system Guide users to preferred system Reduce complexity Eliminate inventory duplications
Metallic Tubing Committee
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