Browse Topic: Ferrous metals

Items (12,912)

Steel, Corrosion- and Heat-Resistant, Investment Castings, 19Cr - 12Ni - 1.0Cb (Nb), Solution Heat Treated

4/22/2026

This specification covers a corrosion- and heat-resistant steel in the form of investment castings.

AMS F Corrosion and Heat Resistant Alloys Committee

Steel Bars, Forgings, Mechanical Tubing and Forging Stock, 1.2Cr - 3.25Ni - 0.12Mo (0.07 - 0.13C) (9310), Premium Aircraft-Quality, Electroslag Remelted or Consumable Electrode Vacuum Remelted

AMS6267L (Current)

4/20/2026

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, Investment Castings, 16Cr - 1.9Ni - 0.08N (431), As Cast

AMS5353G (Current)

4/13/2026

This specification covers a corrosion-resistant steel in the form of investment castings.

AMS F Corrosion and Heat Resistant Alloys Committee

Steel, Corrosion- and Heat-Resistant, Sheet, Strip, and Plate, 15Cr - 25.5Ni - 1.2Mo - 2.1Ti - 0.006B - 0.30V (A286), Multiple Melted, 1800 °F (982 °C) Solution Heat Treated, Welding Grade, Precipitation Hardenable

AMS5858F (Current)

4/13/2026

This specification covers a corrosion- and heat-resistant steel in the form of sheet, strip, and plate.

AMS F Corrosion and Heat Resistant Alloys Committee

Steel, Corrosion-Resistant, Bars, Wire, Forgings and Forging Stock, 18.5Cr - 10Ni - 0.22Se (303Se), Free-Machining; for Swaging or Upsetting, Solution Heat Treated

AMS5641K (Current)

4/13/2026

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

AMS F Corrosion and Heat Resistant Alloys Committee

Steel Bars, Forgings, and Tubing, Nitriding, 1.4Cr - 1.2Mo - 0.3V (0.29 - 0.36C), (32CrMoNiV5), Double Vacuum Melted, Premium Aircraft-Quality for Bearing Applications

AMS6498C (Current)

4/9/2026

This specification covers a nitriding grade of premium aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock. AMS6496 and AMS6497 cover UNS K23280 with other quality levels.

AMS E Carbon and Low Alloy Steels Committee

Steel, Sheet, Strip, and Plate, 0.75Si - 0.62Cr - 0.20Mo - 0.10Zr (0.10 - 0.17C) (NAX 9115-AC)

AMS6354H (Current)

4/8/2026

This specification covers a low-alloy steel in the form of sheet, strip, and plate 4.00 inches (101.6 mm) and under in thickness.

AMS E Carbon and Low Alloy Steels Committee

Strain-Based Fracture Assessment of Tailor Welded Blanks under Complex Loading Conditions

2026-01-0231

4/7/2026

Tailor Welded Blanks are critical for automotive lightweighting yet prone to premature failure due to differential thickness and strength across the weld. This study utilized digital image correlation (DIC) to analyze the maximum in-plane principal Hencky strain (E₁max) and axial strain (εₐₓₐₗ) of TWBs under complex loading conditions, including biaxial and plane-strain states. Twelve distinct material stack-ups were tested to evaluate the impact of material difference on formability. Results indicated that differential properties significantly altered strain distribution, often forcing localization onto the thinner or softer sheet. While UHSS welds provided high load capacity with limited ductility, combinations using HSLA or IF substrates were susceptible to early localization and unstable fracture. Comparative heatmaps illustrate strain evolution across all samples, providing spatial insights beyond conventional force–displacement analysis. Metallurgical characterization confirmed a

Aminzadeh, Ahmad, Sheng, ZiQiang, Huang, Lu, McCarty, Eric, Biro, Elliot

Effective Prediction of the Mechanical Properties of Glue-Laminated Motor Stator Core with Consideration of Glue Disposition

2026-01-0177

4/7/2026

This study presents an effective predictive methodology for determining the mechanical properties of glue-laminated motor cores, with explicit consideration of glue disposition, including bonding pattern, configuration, location, and coverage. In laminated stator cores, glue bonding and stacking processes jointly govern the mechanical integrity of the lamination stack. Practical production bonding schemes are typically nonuniform and localized, leading to spatial variations in stiffness and to locally anisotropic, orthotropic material behavior. These effects influence both the in-plane and through-thickness stiffness of the stator core. They can significantly affect the accuracy of structural simulations, such as NVH responses of high-speed traction motors and e-drive systems. Given the constituent material properties of the electrical steel laminations and the glue, this work distinguishes the governing mechanisms underlying the equivalent core properties. The in-plane stiffness is

Nie, Zifeng

Multi-Material Topology Optimization Using Difference-Based Equivalent Static Load Method

2026-01-0173

4/7/2026

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

Machine Learning-Based Prediction of Tensile Properties in Cast Stainless Steel Influenced by Chemical Composition Variation

2026-01-0237

4/7/2026

In the category of cast stainless steels, there are several variants per different level of addition of chromium, vanadium along with some minor elements, such as molybdenum, niobium, tungsten 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, the effects of each element on the tensile properties of the selected cast stainless steel are studied. The machine learning 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

Tensile and Fatigue Behavior of High Pressure Die Cast AE44 Magnesium Alloy at Elevated Temperatures

2026-01-0234

4/7/2026

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 loading at the temperature below 200°C. With increasing temperature, the anelasticity disappears, and tensile and cyclic behaviors become like 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 found to be 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

Optimizing Joint Efficiency in Stainless Steel-Aluminum Alloy FSW Joints through Advanced Parameter Control

2026-01-0228

4/7/2026

The present study investigates optimization of ultimate tensile strength (UTS) in FSW of AA2024-T3 and SS304 in a butt joint configuration. An L18 mixed-level orthogonal array was used to design 18 experiments, varying tool rotational speed (450, 560, and 710 rpm), traverse speed (20, 25, and 40 mm/min), and pin offset (1 and 1.5 mm toward the Al side). The tool rotational speed had the greatest influence on UTS, contributing nearly one-third of the total variance, followed by pin offset and traverse speed. The optimal combination, 450 rpm, 20 mm/min, 1.5 mm offset, yielded a UTS of 344.7 MPa and a joint efficiency of 78.3%. At this setting, peak temperatures reached ~356 °C, ensuring sufficient plasticization and uniform mixing of the Al–SS interface, producing a refined stir zone with an average grain size of 4.2 μm. Fracture analysis revealed ductile failure at the optimal parameters, whereas suboptimal conditions resulted in brittle or mixed fractures due to either insufficient or

Mir, Fayaz Ahmad, Khan, Noor Zaman, Pali, Harveer Singh

Comparison of Formability Performance Between CR550LA and CR590DP

2026-01-0178

4/7/2026

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 CR420LA and CR550LA are evaluated in overall formability and in-use performance when compared to CR590 dual phase (DP) grade. The evaluations performed

Shih, Hua-Chu, Brown, Lindsay, Pednekar, Vasant, Shi, Ming, Tedesco, Sarah

NASA Tech Briefs: April 2026

26AERP044/2/2026

Leonardo DRS Expands Production Capacity to Advance Naval Power, Sensors, and AI-Driven Mission Systems Success at Sea: NIWC Atlantic Uncrewed Surface Vessel Completes Fastest Transatlantic Crossing High‑Speed Spindles Unlock Five‑Axis Machining Innovation with Smaller Tools Why CFD is Stuck in the File Era Accurate and Resilient GNSS Timing Modules for Critical Infrastructure Undetectable Ship-to-Ship Laser Communications EP40: Structural Epoxy Used for Steel Bonding in Marine Applications Master Bond EP40 is a two-part, room temperature curing epoxy for bonding, sealing, coating, and encapsulating. EP40 bonds well to a variety of substrates, including naval steel, the primary structural metal used in the shipbuilding industry Vortex Research to Solve Aviation's Efficiency Tradeoff with Active Strakes A research team developed a smart strake system that dynamically adapts to flight conditions, showing a promising drag reduction in the wind tunnel with respect to passive strakes. This

Advancing Steel Joining: A Critical Review of Adhesives and Sealants for High-Performance Automotive and Construction Applications

05-19-04-0025

3/31/2026

For centuries, steel has been a cornerstone material for structural construction; by contrast, adhesive joining is a relatively nascent technology, particularly in heavy structural applications. The present article aims to provide the reader a review of the applications of adhesive joining in steel-based applications. Steel being a popular material in many industries due to its excellent mechanical properties, but traditional joining methods might have certain limitations viz. ability to withstand vibrations or movement, distortion, difficult to repair, and the like. Adhesive joining provides an alternative approach that offers advantages like reduced weight, improved corrosion resistance, enhanced aesthetics, ability to join multi-materials, ability to resist vibrations to a certain limit, and the like. This article examines the use of steel within the automotive and construction industries, intentionally narrowing its scope from steel’s broader range of applications. This article

S., Shrray, Arora, Kanwer Singh

Steel, Corrosion-Resistant, Sheet, Strip, and Plate, 15Cr - 6.5Ni - 0.75Mo - 0.30Cb - 1.5Cu (Custom 450), Consumable Electrode Melted, Solution Heat Treated, Precipitation Hardenable

AMS5859G (Current)

3/25/2026

This specification covers a premium aircraft-quality, corrosion-resistant steel in the form of sheet, strip, and plate.

AMS F Corrosion and Heat Resistant Alloys Committee

Steel Cleanliness, Premium Aircraft-Quality, Magnetic Particle Inspection Procedure

AMS2300N (Current)

3/25/2026

This specification covers steel cleanliness requirements for premium 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, Corrosion- and Heat-Resistant, Bars, Wire, Forgings, Forging and Ring Stock, Mechanical Tubing, and Rings, 12.5Cr (SAE 410), Aircraft Quality, Annealed

AMS5613T (Current)

3/13/2026

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

Steel Cleanliness, Special Aircraft-Quality, Magnetic Particle Inspection Procedure

AMS2304D (Current)

3/13/2026

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 Procedure

AMS2301M (Current)

3/13/2026

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 Bars, Forgings, Mechanical Tubing and Forging Stock, Nitriding, 1.4Cr - 1.2Mo - 0.3V (0.29 - 0.36C) (32CrMoNiV5), Aircraft-Quality for Bearing Applications

AMS6496C (Current)

3/13/2026

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

Minimizing Stress Corrosion Cracking in Wrought Forms of Steels and Corrosion-Resistant Steels and Alloys

ARP1110E (Current)

3/13/2026

The purpose of this SAE Aerospace Recommended Practice (ARP) is to provide the aerospace industry with recommendations concerning the minimization of stress corrosion cracking in wrought heat-treatable carbon and low-alloy steels and in austenitic, precipitation hardenable, and martensitic corrosion-resistant steels and alloys. The detailed recommendations are based on laboratory and field experience and reflect those design practices and fabrication procedures which should avoid in-service stress corrosion cracking.

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 Packaging

AMS6375F (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 Relieved

AMS6365M (Current)

3/3/2026

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 Cast

AMS7310M (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 Room

2026-01-7022

2/27/2026

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 Thickness

10-10-02-0017

2/23/2026

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 Method

AMS2484D (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

Effect of Sebastiana Rostrata Fiber Loading on the Tribological Behaviour of Polycaprolactone Biocomposite

2026-28-0021

2/12/2026

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.

Evolution of a Novel Hybrid Stab-Link for a Born Electric Sports Utility Vehicle

2026-28-0001

2/12/2026

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

Modelling and Analysis of Complex Shaped Cracks

2026-28-0048

2/12/2026

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

Quality Assurance Sampling and Testing, Carbon and Low-Alloy Steel Forgings

AMS2372J (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- 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

Steel, Corrosion-Resistant, Bars, Wire, Forgings, Mechanical Tubing and Forging Stock, 16Cr - 2.5Ni (SAE 51431), Aircraft Quality

AMS5628G (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 Strength

AMS5342G (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 S66286

AS3652A (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 Packaging

AMS6458L (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

Improvement Study of Style Steel Wheel Durability in Multiple Pothole Impacts

2026-26-0539

1/16/2026

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

Experimental Evaluation of High Energy Impact Test of Wheel Rim

2026-26-0504

1/16/2026

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

Experimental Study on the Role of Hole Expansion Ratio in Enhancing Crashworthiness of Advanced High Strength Steel

2026-26-0295

1/16/2026

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

Non-Metallic Inclusions in Carburizing Steels as a Contributory Factor for the Formation of Carbide Net

2026-26-0290

1/16/2026

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

Niobium Alloyed Brake Disc for reduced NVH and Emission Control

2026-26-0285

1/16/2026

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

Optimization of Global and Local Formability Properties through Nb Microalloying

2026-26-0303

1/16/2026

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

Hydrogen Embrittlement in Galvanized High Carbon Steel Components of Automotive Seat Slider Assembly

2026-26-0302

1/16/2026

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

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 Manufacturing

2026-26-0486

1/16/2026

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

Design and Development of a Lightweight Aluminium Cascade System for Type IV COPVs for Stationary and Mobile Applications

2026-26-0485

1/16/2026

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

Evaluation of Shear Trim Edge in HSLA Steel for Automotive Application

2026-26-0286

1/16/2026

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

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