Browse Topic: Ferrous metals

Items (13,088)

Characterization of Cut and Chip Damage in Ultra Low Rolling Resistance Tire for Electric Vehicles

2024-28-0175To be published on 12/05/2024

Since the inception of battery driven electric vehicles in the automotive world, there has been a constant challenge in maximizing the range of an electric vehicles through various means including battery technology, vehicle weight optimization, low drag coefficients etc. The tires being a viscoelastic composite material have now become a vital to the range performance of an EV. The rolling resistance of a tire is now become a hotter topic than ever. The rolling resistance coefficient (RRC) is the measure of energy loss during rolling due to viscoelastic dissipation in the tire. The viscous dissipation in tire arises due to hysteresis in the various components of a tire including tread, sidewall, inner liner, apex etc rubber compounds. The internal friction between layers of body ply, steel belts and tread crown ply also contribute to the internal heat generation. Therefore, the development of ultra-low RRC tires is a serious challenge for tire engineers. Nevertheless, the recent

Mishra, Nitish, Singh, Ram Krishnan

Evaluation of joining performance of different coated steel sheets used in automotive applications

2024-28-0163To be published on 12/05/2024

To meet corrosion target of automotive vehicles, different coated steel sheets are used in various parts of body in white, chassis and powertrain. Hot dip galvanized (GI) and hot hip galvannealed(GA) are the two most commonly used steel sheets across world. Other coatings such as Zn-Ni, Al-Si , Zn plating and electro galvanized zing coating are application specific coating, which are used suitably to meet different performance requirement. To meet robust corrosion and performance requirement, there is trend of increase in coated steel sheet use in automotive vehicle. While different coated steels are having different corrosion performance, they also exhibit different joining and paint adhesion performance. Spot welding is the most common technique used for joining automotive parts. Joint strength majorly depends on steel base material grade, chemistry and properties. However, coating on base material also influence joining performance. Major challenge is faced when different coated

Jain, Vikas, Misal, Swapnali, Deshmukh, Mansi, Paliwal, Lokesh

Microstructural characterization of aluminum alloys used in automotive body parts

2024-28-0157To be published on 12/05/2024

To meet light-weighting and safety target of automotive vehicles, different aluminum alloys are used in various body parts. Apart from conventional manufacturing process of gravity die casting (GDC), advanced manufacturing process such as low pressure die casting (LPDC), high pressure die casting (HPDC) and extrusion processes are also used to form complex automotive body parts. Steel parts are majorly used in automotive applications across world. However, steel has limitations with respect to light-weighting. To achieve light-weighting, now a days, there is trend to use these complex aluminum parts in automotive industry to replace steel and integrate multiple parts into single part. Aluminum has emerges as great potential for light-weighting and reducing complexity of handling multiple parts at automotive plant. Aluminum provide additional benefits of high durability and crash performance. There is challenge to identify suitable etchant for microstructural characterization of

Deshmukh, Mansi, Jain, Vikas, Misal, Swapnali, Paliwal, Lokesh

FLASH® BAINITE: ROOM TEMPERATURE WELDABLE ULTRA HARD 600, HIGH HARD 500, AND ADVANCED HIGH STRENGTH STEEL FOR A-CAB

2024-01-3743

11/15/2024

ABSTRACT Flash® Bainite Processing employs rapid thermal cycling (<10s) to strengthen commercial off the shelf (COTS) steel sheet, plate, and tubing into Ultra Hard 600 Armor, High Hard 500 Armor, and advanced high strength steel (AHSS). In a continuous process, induction technology heats a narrow segment of the steel cross section in just seconds to atypically high temperature (1000-1300°C). Quenching substantially immediately follows. A report by Benet Labs and Picatinny Arsenal, investigating a less mature flash technology in 2011, surmised that the novel flash bainite process for steels has the potential to reduce cost and weight while also enhancing mechanical performance [1]. Receiving five financial grants, the US Dept of Energy has greatly matured flash technology in the last few years and its metallurgical understanding in collaboration with Oak Ridge National Lab and others. DOE has named Flash Bainite as the “SBIR Small Business of the Year” in May 2018 and awarded a Phase 3

Cola, Gary M

HIGH MN, HIGH AL STEELS FOR THICK PLATE ARMOR APPLICATIONS

2024-01-3739

11/15/2024

ABSTRACT FeMnAlC alloys exhibit lower density (6.5-7.2 g/cm3) than traditional military steels (7.9 g/cm3) while maintaining similar energy absorption capabilities. Material substitutions in legacy systems must meet existing form/fit/function requirements, limiting opportunities for lightweighting of existing designs. This study examines production and material properties of thick plate with a nominal chemistry of 30% Mn, 9%Al and 1%C, in the wrought condition. Due to the high aluminum and carbon content, there are unique challenges to large scale (45+ ton heat) production versus typical armor steel chemistries. Lab-scale wrought and production material are characterized, comparing microstructure, and mechanical properties. Processing practices including teeming flux and rolling temperature are discussed. The high manganese content of this alloy presents challenges for welding and machining practices, such as limited compatibility of weld wires and substantial work hardening during

Sebeck, Katherine, Toppler, Ian, Rogers, Matt, Limmer, Krista, Cheeseman, Bryan, Howell, Ryan, Herman, William

Compositional Sensitivity of High Mn, High Al Lightweight Steels

2024-01-3815

11/15/2024

ABSTRACT The family of lightweight high Mn, high Al steels (FeMnAl) exhibit lower density (6.5-7.2 g/cm3) than traditional military steels (7.9 g/cm3). These alloys are precipitation hardened, with κ-carbide dominating hardening performance. This carbide has an E21 perovskite structure with a nominal composition of (Fe,Mn)3AlC. In the literature, a number of studies have examined the sensitivity of mechanical properties to changing a single element in the composition. However, the covariance of the major elements has not been systematically explored. In this study, a series of small ingots were prepared according to a two-factor design of experiments, in addition to analysis of previously generated compositions. Methods of measuring alloy composition will be discussed, along with aging kinetics and key mechanical properties. Citation: K. Sebeck, I. Toppler, K. Limmer, D. Field, D. Wagner, A. Gafner, “Compositional Sensitivity of High Mn, High Al Steels”, In Proceedings of the Ground

Sebeck, Katherine, Toppler, Ian, Limmer, Krista, Field, Daniel, Wagner, Daniel, Gafner, Alyssa

EFFECT OF PRE-BENDING AND HYSTERESIS OF A METAL PLATE ON BLAST-LOADING DEFORMATION: DATA VS. NUMERICAL SIMULATION

2024-01-3641

11/15/2024

ABSTRACT V-shaped hulls for vehicles, to mitigate buried blast loads, are typically formed by bending plate. Such an approach was carried out in fabricating small test articles and testing them with buried-explosive blast load in Southwest Research Institute’s (SwRI) Landmine Test Fixture. During the experiments, detailed time dependent deflections were recorded over a wide area of the test article surface using the Dynamic Deformation Instrumentation System (DDIS). This information allowed detailed comparison with numerical simulations that were performed with LS-DYNA. Though in general there is good agreement on the deflection, in the specific location of the bends in the steel the agreement decreases in the lateral cross section. Computations performed with empirical blast loads developed by SwRI and by more computationally intensive ALE methods in LS-DYNA produced the same results. Computations performed in EPIC showed the same result. The metal plate was then bent numerically so

Walker, James D., Chocron, Sidney, Moore, Thomas Z., Bradley, Joseph H., Carpenter, Alexander J., Weiss, Carl, Gerlach, Charles A., Grosch, Donald J., Grimm, Matt, Burguess, Victor W.

Tech Pub Qualification Scheme Development for Arc Directed Energy Deposition Additive Manufacturing

2024-01-3808

11/15/2024

ABSTRACT A prescriptive qualification scheme was completed for Arc Directed Energy Deposition (DED) metal Additive Manufacturing (AM) processes for austenitic single-sided builds. Robotic arc DED AM qualification builds used stainless steel consumables with the gas metal arc welding - pulse (GMAW-P) process. A matrix of standard qualification builds were made to develop, evaluate, and recommend the preferred process qualification build schemes. The qualification scheme explored a range of heat inputs, deposit sizes, and deposition rates; and the effects of interpass temperature that can be a limiting productivity factor for robotic arc DED metal AM builds. The standard qualification builds evaluated the effects of thickness (thin and thick geometric build features) where the process deposit (heat input) and process build thermal features (preheat and interpass temperature) are controlled over smaller ranges. The builds were examined with both ultrasonic and radiographic inspection, and

Harwig, D.D, Mohr, W., Hovanec, S., Rettaliata, J., Hayleck, R., Handler, E, Farren, J.

FORMING AND WELDING INNOVATIONS FOR ARMOR STEELS

2024-01-3740

11/15/2024

ABSTRACT This paper reviews research that has been conducted to develop inductively assisted localized hot forming bending technologies, and to use standardized welding tests to assess the practicality and potential benefits of adopting stainless based consumables to weld both existing and evolving armor alloys. For the titanium alloy Ti6Al4V it was determined that warming the plate to circa 600°F would improve the materials ductility (as measured by reduction of area) from ~18 to 40% without exposing the material to a temperature at which atmospheric contamination would be significantly deleterious. For the commercial alloy BB and class 1 armor alloy it was found that there was little effect on the charpy impact toughness and the proof strength as a result of processing at 900 °F with either air cool or water quench and there was an added benefit of lower residual stresses in the finished bends compared to cold formed bends. Heating “alloy BB” to 1600 °F followed by water quench

Lawmon, John, Alexandrov, Boian, Duffey., Matthew, Ngan., Tiffany

STRUCTURAL ADHESIVE WITH COMBINED HIGH STRENGTH AND DUCTILITY FOR MULTIMATERIAL JOINING AND GALVANIC ISOLATION

2024-01-3735

11/15/2024

ABSTRACT A newly developed structural adhesive demonstrates a unique combination of high strength (43 ± 2 MPa) and displacement (4.7 ± 1.2 mm) in aluminum lap joint testing. Bulk material characterization of the prototype adhesive reveals its extreme ductility, with nearly 80% shear strain before failure and a 2.5-fold increase in strain energy density as compared to commercial structural adhesives. The prototype adhesive is found to maintain 67 to 82% of its initial strength under extreme environmental conditions, including at high temperatures (71°C), after high humidity (63°C hot water soak, 2 weeks), and after corrosive conditions (B117 salt spray, 1000 hours). The prototype structural adhesive is shown to also generate high strength bonds with multiple substrates, including steel, carbon fiber, and mixed material joints, while also providing galvanic isolation

Pollum, Marvin, Kriley, Joseph, Nakajima, Masa, Tan, Kar Tean, Stalker, Jeffrey, Fleischauer, Richard, Rearick, Brian

Investigation of Hot Cracking Phenomena in Light-Weight Armor Steel Based on the FeMnAl-C Alloy System

2024-01-3738

11/15/2024

ABSTRACT The US Army TARDEC has been researching an alternative to current armor steel that is both tough, and light-weight. The studied alloy is based on the Fe-Mn-Al-C system. This study was conducted to investigate and quantify this alloy’s susceptibility to hot cracking phenomena related to casting and welding. Very little research has been done on general weldability of this alloy system, so the results of these tests will be compared to other high Mn steels, and alloys that have undergone cast pin tear testing. Testing will be conducted utilizing button melting tests, autogenous spot welds, and cast pin tear testing. The cast pin tear testing was conducted to measure this alloys susceptibility to weld solidification cracking. The spot welds were used to quantify the susceptibility of the weld heat affected zone (HAZ) to liquation cracking, as well as to observe the solidification structure of the fusion zone. The testing results showed that the FeMnAl system in its current form

Evans, William, Ramirez, Antonio J., Sebeck, Katherine

EVALUATION OF CANDIDATE METHODS FOR WELDING STEEL TO OTHER STRUCTURAL LIGHTWEIGHT METALS

2024-01-3741

11/15/2024

ABSTRACT This paper addresses candidate technologies for attaching steels to selected lightweight materials. Materials of interest here include aluminum and titanium alloys. Metallurgical challenges for the aluminum-to-steel and titanium-to-steel combinations are first described, as well as paths to overcome these challenges. Specific joining approaches incorporating these paths are then outlined with examples for specific processes. For aluminum-to-steel joining, inertia, linear, and friction stir welding are investigated. Key elements of success included rapid thermal cycles and an appropriate topography on the steel surface. For titanium-to-steel joining, successful approaches incorporated thin refractory metal interlayers that prevented intimate contact of the parent metal species. Specific welding methods employed included resistance mash seam and upset welding. In both cases, the process provided both heat for joining and a relatively simple strain path that allowed significant

Gould, Jerry E., Eff, Michael, Namola, Kate

DEVELOPMENT OF A SCALABLE THERMOMECHANICAL PROCESS (TMP) FOR THICK BAINITIC ARMOR STEEL

2024-01-3745

11/15/2024

ABSTRACT A bainite phase-based alloy and associated thermomechanical process were developed to produce (2.5 to over 5 cm) thick armor-grade steel with uniform through-thickness high hardness and strength. The alloy composition and the final-critical (austenite to bainite) isothermal transformation step were specifically designed to utilize a simple and versatile air-cool/quench method to keep a low upfront capital cost and to provide the ability to continuously control the cooling rate in real time, in order to produce maximum volume fraction of bainite phase, and promote uniformly distributed strength and hardness. Final thickness of 1.9 cm and 5.7 cm steel plates were fabricated for characterization, testing and evaluation and found to possess uniform through-thickness hardness between 53 to 55 HRC and dynamic compressive strength of up to 2 GPa

Chu, Henry S., Lillo, Thomas M., Anderson, Jeffrey A., Zagula, Thomas A.

RELIABILITY OF POWERTRAIN COMPONENTS EXPOSED TO EXTREME TRIBOLOGICAL ENVIRONMENTS

2024-01-3175

11/15/2024

ABSTRACT Results are presented from tests on a formulated 15W-40 mil-spec engine/transmission fluid to examine the impact of additives on improving its reliability and durability under extreme tribological conditions. A block-on-ring (BOR) configuration was used to measure the effect of five additives (an emulsion-based boric acid, tricresyl phosphate, particulate-based boron nitride, particulate-based MoS2, and particulate-based graphite) on the critical scuffing load as a function of additive concentration and time to scuff during oil-off tests (starved lubrication). A four-ball configuration was used to evaluate the impact of simulated engine grit/sand on the abrasive wear of steel as a function of grit size and loading. The results demonstrated that the additives increased the load for scuffing by 50 to 100% for the formulated oil and by 50 to 150% for the unformulated base fluid used in the formulated oil. Two of the additives (emulsion-based boric acid and tricresyl phosphate

Fenske, G. R., Ajayi, O. O., Erck, R. A., Lorenzo-Martin, C., Masoner, Ashley, Comfort, A. S.

FLASH® 600 ULTRA HIGH HARD: ROOM-TEMP ER120S-1 WELDABILITY TEKKEN, H-PLATE, BALLISTIC, & FSP DATA FOR IMPROVED SURVIVABILITY

2024-01-3900

11/15/2024

ABSTRACT Survivability of a welded vehicle hull is directly tied to the performance of the grade of steel armor used. Selecting the highest performing grade of armor that can be welded into a specific location on a vehicle will improve survivability. While rolled homogeneous armor is the simplest to weld, challenges in welding high hard, and especially ultra high hard, are well known. Preventative measures to avoid weld cracking in vehicle structures can lead to increased costs during fabrication. Cracking of welds, both seen and unseen, in deployed vehicles directly impacts the survivability of the vehicle. Weld cracking during deployment further magnifies repair costs and leads to non-mission capable status. This analysis examines the weldability, ballistic/blast performance, and underlying metallurgy of Flash® Processed steels that have been tested by Army, Academia, and Industry. Citation: G. Cola, “Flash® 600 Ultra High Hard: Room-Temp ER120S-1 Weldability Tekken, H-Plate

Cola, Gary M

HIGH PERFORMANCE CONTROLLERS BASED ON REAL PARAMETERS TO ACCOUNT FOR PARAMETER VARIATIONS DUE TO IRON SATURATION

2024-01-3391

11/15/2024

ABSTRACT With the increase in electric power on military ground vehicle platforms, electrically driven accessories are replacing existing hydraulic, belt, and gear-driven loads. Permanent Magnet Synchronous Machines (PMSM) are often selected to drive these accessories, and are under consideration for the main engine generator, due to their torque density and efficiency being among the highest available. To maximize the efficiency of a PMSM, accurate knowledge of its parameters is required across the entire operating range. Efficient control of the onboard electric drives will help reduce fuel consumption in the ground vehicle fleet. This paper presents the effects of iron saturation on the performance of a PMSM drive. Iron saturation depends on the amount of current injected into the motor and it restricts the amount of flux linkage that can be generated. PMSMs are controlled using a two axis space vector representation. Ideally, the control is decoupled, such that the flux linkage

Cintron-Rivera, Jorge G., Foster, Shanelle N., Zanardelli, Wesley G., Strangas, Elias G.

UTILIZING ADDITIVE MANUFACTURING TO ENABLE LOW-COST, RAPID FORMING OF HIGH TEMPERATURE LIGHTWEIGHT GROUND VEHICLE STRUCTURES

2024-01-3926

11/15/2024

ABSTRACT Barriers to the introduction of composite materials for ground vehicle applications include material property selection and cost effective material processing. Advancements in processing of thermoplastic composites for use in applications for semi structural and structural applications have created opportunities in “Out of Autoclave” processing utilizing preconsolidated unidirectional reinforced tapes. Traditional tooling for the bending formation of high temperature reinforced structural thermoplastic laminates typically involves matched metal tooling consisting of steel or aluminum and are costly and heavy. In this research, a comparative analysis was performed to evaluate the use of a large scale 3D printed forming tool in comparison to a traditional metallic mold. Material processing considerations included the development of a technique for localized laminate heating to achieve optimized energy input in the forming process. Considerations in tooling development included

Erb, David, Dwyer, Benjamin, Roy, Jonathan, Yori, William, Lopez-Anido, Roberto A., Smail, Andrew, Hart, Robert

AN IMPROVED METHOD TO MORE ACCURATELY ASSESS THE JOHNSON-COOK HIGH STRAIN-RATE DEFORMATION MATERIAL MODEL PARAMETERS - PART I

2024-01-3553

11/15/2024

ABSTRACT Two relevant materials found in ground vehicle underbody armor/hull designs are Aluminum 2139-T8 and RHA Steel (Class I). These are 2 very important materials that need a thorough understanding of their high-strain rate behavior. The Johnson-Cook Deformation (JC-D) model at this time is the most preferred constitutive material model to utilize for high-strain (large deformation) blast simulations. The JC-D Model contains five empirically-based input parameters which can be determined traditionally through a series of uniaxial laboratory tests where each target parameter is isolated, while the remaining parameters are held constant. There are many criticisms and problems with this approach. The objective of this two part paper is to present and adopt a more accurate approach with less criticism to the determination of these five input parameters through both a sensitivity study to determine which input parameters are the most sensitive to a particular chosen response which in

Hause, Terry, Sheng, Jianping

SUPERIOR BALLISTIC AND BLAST RESISTANCE IN ATI TITAN 27™ ALLOY WITH A NOVEL DEFORMATION MECHANISM

2024-01-3986

11/15/2024

ABSTRACT α-β titanium alloys are used in armor plate applications due to their capability to defend against ballistic threats while having a 40% lower density than steel. ATI 425® was developed as a cold-deformable alternative to Ti-6Al-4V with similar ballistic properties and improved blast performance owing to the alloy’s higher damage tolerance. ATI Titan 27™ is an evolutionary step forward on ATI 425® Alloy, and is being developed as a higher-performance titanium armor alloy owing to its greater than 10% improvement in strength with similar ductility and formability. Recent work has demonstrated a novel deformation mechanism that explains the improved cold deformation observed in both alloys over Ti-6Al-4V. This mechanism, a twinning of α-phase coinciding with slip in the β-phase, is unique among high-strength titanium alloys. Moreover, twinning is well known to be suppressed with high oxygen content, and ATI Titan 27™ Alloy has one of the highest oxygen targets across high

Foltz, John, Ruiz-Aparicio, Luis, Berry, David, Porter, Rick

Feasibility of Joining Wrought Homogenized Armor Steel with Friction Stir Welding

2024-01-3811

11/15/2024

Abstract The United State Army employs several advanced armored combat vehicles, in a wide array of different environments, and applications. Armor steels are hard and are required to meet certain conditions to stay within the military’s specifications for armored steels. Vehicle armor is typically joined using arc welding methods. Joining via arc welding degrades armor material below specification, so alternate joining methods are being explored like Friction Stir Welding (FSW). FSW is a solid-state joining technique that utilizes a rotating pin to stir plasticized material and use a tool shoulder to forge the material into the joint. The advantages come from the reduction in peak temperature, an increase in mechanical performance, and a decrease in possible defects that occur. In this study FSW parameters were developed and used to weld Wrought Homogenous Armor (HRA) steel. The welds were subject to hardness indention, and metallographic analysis to observe an early prediction of

Evans, William, Ramirez, Antonio, McDonnell, Martin, Eff, Mike

STRUCTURAL REPAIR FOR STRYKER HH STEEL BODY PANELS USING COLD SPRAY

2024-01-3814

11/15/2024

ABSTRACT Corrosion damage to military ground vehicles costs the U.S. Army around $1.6B per year. A large part of that cost is related to keeping vehicles like the Stryker at their full fighting capability. Corrosion damage has been a common finding on Stryker vehicles and even light corrosion damage, which often reaches 10% of the body thickness or more, can degrade its armor protection rating and require replacement. Recently, cold spray deposition has been shown to be capable of restoring the full ballistic resistance of corrosion damaged high hard steel armor panels. These repairs can be done on-vehicle in depot facilities, using mobile high-pressure cold spray systems. This repair capability can reduce the number of entire side, roof, and floor panels that need to be cut out and re-welded in, which is the only currently approved repair operation for corrosion damage that exceeds allowable depths. Citation: V.K. Champagne, C.A. Widener, A.T. Nardi, G.D. Ferguson, “Structural Repair

Champagne, Victor K., Widener, Christian A., Nardi, Aaron T., Ferguson, Gehn D.

Test the Corrosion Effect on High Hard Steel Armor MIL-DTL-46100 Coated with Stellite 6 Applied by Direct Energy Deposition Method

2024-01-3813

11/15/2024

ABSTRACT The U.S. Army - GVSC Materials Characterization and Failure Analysis team conducted a preliminary study in FY18 to address the issue of galvanic and pitting corrosion of U.S. Army ground vehicle system (GVS) structural surfaces. The objective of this study was to develop a permanent coating solution to supplement the existing corrosion protective coating of zinc rich primer and CARC paint, and extend the lifecycle of the armor. Twenty-five permanent, 0.1 inch layer, additively manufactured (AM) coated coupons of deposited Stellite 6 cobalt alloy on MIL-STD-46100 High Hard (HH) armor steel blocks were produced for cyclic testing using an un-optimized set of parameters. These coupons were subjected to a twenty-four week study in accelerated corrosive conditions of a fog spray chamber alongside primer-CARC coated and uncoated coupons. The resulting study showed no signs of pitting corrosion in the surface of the AM coated coupons, and minimal galvanic corrosion. Citation: I

Toppler, Ian J, Schleh, Daniel C, Romero, Claudio Gutierrez

Comparative Investigations of Tool Wear and Cutting Force for Wet and Dry Turning of Super Duplex Stainless Steels 2507

05-18-02-0012

11/07/2024

Super Duplex Stainless Steels (SDSS) are attracting attentions of the manufacturing industries due to the excellent corrosion resistance to critical corrosion. But SDSS2507 is the hardest to machine with lowest machinability index among DSS family. Moreover, formation of built-up layer (BUL) and work hardening tendency makes it further difficult to machine. Researchers have the conflict in opinions on using wet machining or dry machining using tool coatings. In this investigation SDSS2507 machining is carried out using uncoated and PVD–TiAlSiN-coated tools. The wet and dry machining environment are compared for increase in cutting speed from 170 m/min to 230 m/min. Excellent properties of PVD–TiAlSiN coatings exhibited microhardness of 39 GPa and adhesion strength of 88 N, which outperformed the uncoated tools. Tool life exhibited by coated tools was four times higher than uncoated tools. Wet machining was found to be ineffective when PVD-coated tools are used, exhibiting the same

Sonawane, Gaurav Dinkar, Bachhav, Radhey

Performance Optimization of Ti-Steel Laser-Welded Joints Based on Optimized Support Vector Machine and Multi-Objective Salp Swarm Algorithm

05-18-02-0010

11/07/2024

The dissimilar welding of titanium to steel enables the integration of the advantageous properties of both metals, facilitating the design of lightweight, corrosion-resistant, and high-strength multifunctional composite structures. However, significant differences in their thermophysical properties pose substantial technical challenges in practical welding scenarios, necessitating careful selection of process parameters to enhance the quality and performance of the weld joint. This article establishes a support vector machine (SVM) model with laser power, welding speed, and laser spot diameter as independent variables, and the maximum residual stress and minimum yield strength of the weld joint as dependent variables. To improve prediction accuracy, the SVM model is optimized using the beluga whale optimization (BWO) algorithm. Taking the established model as the objective function, the multi-objective salp swarm algorithm (MSSA) is employed to optimize the laser welding process

Zhu, Yubin, Meng, Xiangli, Zhang, Xinran

Steel, Corrosion-Resistant, Sheet, Strip, and Plate 19Cr - 9.2Ni (304) Cold Rolled, 1/4 Hard, 125 ksi (862 MPa) Tensile Strength

AMS5910D (Current)

11/06/2024

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, Corrosion Resistant Bars and Forgings 12.5Cr - 1.0Ni - 15.5Co - 2.0Mo Vacuum Induction Plus Vacuum Consumable Electrode Remelted

AMS5933B (Current)

11/06/2024

This specification covers a premium aircraft-quality corrosion-resistant steel in the form of bars, forgings, and forging stock

AMS F Corrosion and Heat Resistant Alloys Committee

Steel Bars, Forgings, Mechanical Tubing and Forging Stock 4.1Cr - 4.2Mo - 1.0V (0.80 - 0.85C) (M-50) Premium Aircraft-Quality for Bearing Applications, Double Vacuum Melted

AMS6491G (Current)

11/06/2024

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

Steel, Corrosion-Resistant, Bars, Forgings and Forging Stock 10Cr - 5.5Ni - 14Co - 2Mo - 1W (0.19-0.23C), Premium Aircraft Quality, Vacuum Induction Melted, Vacuum Arc Remelted, Normalized and Annealed

AMS5922D (Current)

11/06/2024

This specification covers a corrosion-resistant, premium aircraft-quality alloy steel in the form of bars, forgings, and stock for forging

AMS F Corrosion and Heat Resistant Alloys Committee

INSERT - CRES HELICAL COIL FINE THREAD, LOCKING (LOW FRICTION SYSTEMS) 3 DIA NOM LENGTH

AS3097B (Current)

11/06/2024

E-25 General Standards for Aerospace and Propulsion Systems

INSERT - CRES HELICAL COIL FINE THREAD, LOCKING (LOW FRICTION SYSTEMS) 2.5 DIA NOM LENGTH

AS3096B (Current)

11/06/2024

E-25 General Standards for Aerospace and Propulsion Systems

Steel, Corrosion-Resistant, Bars, Wire, Mechanical Tubing, Forgings and Forging Stock 15.5Cr - 1.5Si - 0.3Mo - 0.1N (0.45 - 0.60C) for Bearing Applications

AMS5926A (Current)

10/28/2024

This specification covers a corrosion- and heat-resistant steel in the form of bars, wire, mechanical tubing, forgings, and forging stock

AMS F Corrosion and Heat Resistant Alloys Committee

Steel, Nitriding, Bars, Forgings, Mechanical Tubing and Forging Stock Aircraft Quality 1.1Cr - 3.5Ni - 0.25Mo - 1.2Al (0.21 - 0.26C

AMS6475M (Current)

10/28/2024

This specification covers an age-hardenable nitriding grade of aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock

AMS E Carbon and Low Alloy Steels Committee

Categorization and Properties of Low-Carbon Automotive Sheet Steels

J2329_202410 (Current)

10/28/2024

This SAE Recommended Practice establishes mechanical property ranges for low-carbon automotive hot-rolled sheet, cold-rolled sheet, and metallic-coated sheet steels. It also contains information that explains the different nomenclature used with these steels

Metals Technical Committee

Steel, Corrosion- and Heat-Resistant, Bars, Wire, Forgings, Mechanical Tubing, Rings, and Stock for Forging and Rings 17Cr - 12Ni - 2.5Mo (0.030 Max C) (316L), Solution Heat Treated

AMS5653K (Current)

10/21/2024

This specification covers a corrosion- and heat-resistant steel in the form of bars, wire, forgings, mechanical tubing, flash-welded rings, and stock for forging or flash-welded rings

AMS F Corrosion and Heat Resistant Alloys Committee

Optimizing Cutting Parameters for Effective Turning of EN-31 Steel by Utilizing Vegetable-Based Cutting Fluids as a Coolant

05-18-01-0006

10/12/2024

The primary objective of this article is to study the improvement of machining efficiency of EN-31 steel by optimizing turning parameters using newly developed cutting fluids with different proportions of aloe vera gel and coconut oil, utilizing the Taguchi technique. Furthermore, performance metrics including material removal rate (MRR), surface roughness, and tool wear rate (TWR) were assessed. Analysis of variance (ANOVA) suggested that as cutting speed and feed increase, the MRR is positively influenced, but likewise tool wear is intensified. The surface roughness exhibited a positive correlation with cutting speed, and a negative correlation with increasing both cutting speed and feed. It was found that the maximum MRR value was attained at a cutting speed of 275 m/min, a feed rate of 1.00 mm/rev, and a cutting fluid composition of 30% aloe vera and 70% coconut oil. For the best surface smoothness, it is advisable to adjust the cutting speed to 350 m/min and the feed rate to 0.075

Premkumar, R., Ramesh Babu, R., Saiyathibrahim, A., Murali Krishnan, R., Vivek, R., Jatti, Vijaykumar S., Rane, Vivek S., Balaji, K.

Experimental Investigation of Electro-Discharge-Machined EN-24 and EN-42 Alloys

05-18-01-0005

10/04/2024

The EN24 and EN42 materials were machined by the electric discharge machine (EDM). The study aimed to optimize the input variables for the multiple outputs, such as metal removal rate (MRR), tool wear rate (TWR), and surface roughness. The machining of the metal is essential to analyze the surface quality and the production rate. The MRR is a prediction of the production rate and surface roughness resembling the quality of the surface. The input variables were current (A), pulse on time (ton), and pulse duty factor (T). The three levels of current were 3A, 6A, and 9A. The ton time was selected as 30 μs, 50 μs, and 70 μs. The pulse duty factors were selected as 4, 5, and 6. The Taguchi optimization techniques are used to optimize process parameters. The L9 orthogonal array was selected for the process. ANOVA analysis was employed to check the rank of the input parameters relative to the output. The maximum MRR were at 9A, 70 μs, and 4 duty factor for the EN24. The best MRR were at 9A

Sahu, Kapil Dev, Singh, Rajnish, Chauhan, Akhilesh Kumar

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

AS9433B (Current)

10/03/2024

E-25 General Standards for Aerospace and Propulsion Systems

Steel, Corrosion- and Heat-Resistant, Bars, Wire, Forgings, Mechanical Tubing, Rings, and Stock for Forging and Rings, 25Cr - 20Ni (310), Solution Heat Treated

AMS5651L (Current)

10/01/2024

This specification covers a corrosion- and heat-resistant steel in the form of bars, wire, forgings, mechanical tubing, flash-welded rings, and stock for forging or flash-welded rings

AMS F Corrosion and Heat Resistant Alloys Committee

Reducing the Weight of EV Batteries with SPECIALTY THERMOPLASTICS

24AUTP10_02

10/01/2024

Eight arguments for these resins, compounds and composites. Weight reduction in EV battery components is an important factor in optimizing battery energy density, which in turn is critical to extending vehicle range and boosting power and performance. Although traditional metals such as steel and aluminum are widely used in EV batteries, the ongoing push for higher energy density is opening new opportunities for thermoplastic resins, compounds, and composites. The main advantage of these materials vs. metals is their inherent lighter weight - particularly in the case of lower-density polymers. Thermoplastics can be 30-50 percent lighter than metals. They also increase design freedom, which permits further weight-out through part consolidation and thin walls

Bobba, Somasekhar

Steel, Corrosion- and Heat-Resistant, Bars, Wire, Forgings, Mechanical Tubing, Rings and Stock for Forging and Flash-Welded Rings, 12Cr (410), Aircraft Quality, Ferrite Controlled, Annealed

AMS5612L (Current)

10/01/2024

This specification covers an aircraft quality, corrosion- and heat-resistant steel in the form of bars, wire, forgings, mechanical tubing, flash-welded rings, and stock for forging or flash-welded rings

AMS F Corrosion and Heat Resistant Alloys Committee

Sheet and Strip, Steel (0.90 - 1.04C) (SAE 1095) Annealed

AMS5121M (Current)

10/01/2024

This specification covers a carbon steel in the form of sheet and strip

AMS E Carbon and Low Alloy Steels Committee

Steel, Extra High Toughness, Corrosion-Resistant, Bars, Wire, Forgings, Rings, and Extrusions 13Cr - 8.0Ni - 2.2Mo - 1.1Al Vacuum Induction Plus Consumable Electrode Melted, Solution Heat Treated, Precipitation Hardened (H1050

AMS5934/H1050 (Current)10/01/2024

This specification covers a corrosion-resistant steel product in the solution and precipitation heat-treated (H1050) condition, 12 inches (305 mm) and under in nominal diameter, thickness, or, for hexagons, least distance between parallel sides

AMS F Corrosion and Heat Resistant Alloys Committee

Iron Could Be Key to Less Expensive, Greener Lithium-Ion Batteries

TBMG-51679

10/01/2024

A collaboration co-led by an Oregon State University chemistry researcher is hoping to spark a green battery revolution by showing that iron instead of cobalt and nickel can be used as a cathode material in lithium-ion batteries

Structural and Thermal Analysis of Brake Disc with Various Composites

2024-28-0066

09/19/2024

The essential aspect of an automobile is its braking system. Brakes absorb the kinetic energy of the rotating parts, i.e., wheels, and dissipate this energy into the surroundings in the form of heat. This entire process is quite complex, and the brake disc is subjected to extreme thermal and structural stresses along with deformation, which might damage the disc. This paper presents a structural and thermal analysis of an Audi Q3 brake disc using an ANSYS 2021-R1. The present brake disc is designed using SOLIDWORKS software. Composite materials are added in the ansys material library by adding their respective characteristics. The thermal analysis mainly focused on temperature variation and directional heat flux. The structural study was conducted to understand the stresses developed during braking and the deformations observed. Along with a comprehensive structural and thermal analysis, this work has also estimated the life of the brake disc, the factor of safety, and the real-time

Bahulekar, Atharv, Shiralkar, Shaunak, Jomde, Amit, Shamkuwar, Sonal, Patane, Prashant, Shinde, Tarang, Dandin, Shahbaz

Wire, Steel 0.18 - 0.23C (SAE 1020) Annealed

AMS5032J (Current)

09/18/2024

This specification covers a low-carbon steel in the form of wire up to 0.249 inch (6.32 mm), inclusive, supplied as coils of wire or, when specified, as straight lengths

AMS E Carbon and Low Alloy Steels Committee

Steel, Corrosion and Heat-Resistant, Bars and Forgings and Forging Stock, 15.5Cr - 4.5Ni - 2.9Mo - 0.10N (AM 355®), Consumable Electrode Remelted, Heat Treated, 170 ksi (1172 MPa) Tensile Strength

AMS5744G (Current)

09/18/2024

This specification covers a corrosion- and heat-resistant steel in the form of bars, forgings, and forging stock

AMS F Corrosion and Heat Resistant Alloys Committee

Modernization and Integration of Technologies for Ground Systems (MINT-GS): Qualification of 17-4PH Stainless Steel Manufactured Using Laser Powder Bed Fusion & Direct Energy Deposition Additive Manufacturing Processes

2024-01-4094

09/16/2024

There is a critical military need to improve readiness and operational performance by utilizing Additive Manufacturing (AM) for the sustainment and modernization of ground vehicles. AM opens the opportunity to add value to the manufacturing of parts and components that may be limited or not achievable by traditional manufacturing methods and materials. Additionally, AM can serve as a secondary source of manufacturing that can solve supply-chain and obsolescence issues at the point of need or point of repair. One of the primary challenges that exists with AM is the lack of defined standards for the qualification of materials and processes. WSU-NIAR is collaborating with the Army Ground Vehicle System Center to address this challenge by establishing a rapid qualification process utilizing Laser Powder Bed Fusion (LPBF) and Direct Energy Deposition (DED) AM processes with 17-4PH stainless steel material applied to ground vehicle parts of need. An overview of the 2023 MINT-GS projects at