Browse Topic: Iron

Items (1,655)
This specification covers an iron-nickel alloy in the form of strip 0.020 to 0.250 inch (0.51 to 6.35 mm), inclusive, in nominal thickness.
AMS F Corrosion and Heat Resistant Alloys Committee
The development of copper-free brake pads poses a significant challenge because copper plays a critical role in tribofilm formation and friction stability. This study proposes a novel approach using a recycled flake iron oxide material, characterized by high thermal stability and a unique plate-like morphology, as a sustainable alternative. The material acts as a friction modifier, promoting the formation of stable tribofilms and serving either as a copper substitute or a functional additive. Its iron-oxide composition ensures strong compatibility with the counterface tribofilm, enhancing adhesive friction, while its role as a primary plateau contributes to friction stability and reduced wear. Three application scenarios were investigated: (i) copper substitution in Low-Steel (LS) and Non-Asbestos Organic (NAO) formulations, (ii) partial replacement of steel fibers in copper-free LS formulations, and (iii) synergistic use with iron sulfide in copper-free NAO formulations. Tribological performance was evaluated using a tribometer, and worn surfaces were analyzed by SEM and EDS to characterize tribofilm formation. Results demonstrate that the proposed material provides friction stability and wear resistance comparable to copper in both LS and NAO formulations. Partial substitution of steel fibers improved wear resistance by up to 75%, while synergistic addition with iron sulfide further enhanced friction and wear performance in copper-free NAO pads. These findings highlight the potential of this recycled material as a sustainable and effective alternative for copper-free brake pads, offering both environmental benefits and high tribological performance while reducing reliance on critical raw materials.
Jara, Diego ChávezLorenzana, Carlos
This study aimed at the characterization and validation of a drum-brake spider with mass reduction, using a new concept of a nanostructured ductile cast iron alloy. There is a well-known effort in developing lighter, more competitive products with higher safety and longer service life for brake systems. One of the approaches that enables this type of development is the use of new materials capable of delivering superior performance. Conventional ductile cast iron alloys used in brake spiders exhibit limited mechanical properties, which restricts mass reduction while still ensuring high durability in service. One way to obtain high-performance ductile cast iron alloys is through heat treatments such as austempering (ADI), which provides significant gains in mechanical strength but involves high cost and environmental liabilities due to the use of salt baths. The modified and nanostructured ductile cast iron alloy proposed in this work exhibited mechanical properties in the as-cast condition that meet the standards for ADI-treated ductile irons, showing an increase of 102% in tensile strength and 78% in yield strength compared to the baseline spider. Based on this new material, a topology optimization was performed on the baseline spider model, resulting in an optimized design with a 40% mass reduction. The model was validated using casting simulation software, and tooling was manufactured for producing the new optimized spider samples in the nanostructured ductile cast iron alloy. Static mechanical properties and microstructure were determined and approved, allowing the fatigue testing phase to proceed. Initially, the spider samples were instrumented with electrical strain gauges and subjected to the standard structural bench test known as the Chuker test, which can simulate real operating conditions of the brake system. Considering that this test requires extended bench time, an accelerated durability test was developed for the new spider model using three servo-controlled hydraulic cylinders, based on the stress levels obtained. The results from the accelerated durability bench test demonstrated superior fatigue life for the optimized spider compared to the baseline model, also validating the new testing procedure.
Titton, Angelo PradellaTuzzin, MatheusLopes, Carlos H. R.Marcon, LucasPereira, LeonardoTedesco, Jaime LuizBoaretto, JoelVieceli, AlexandreKlein, Aloísio N.
This paper presents the optimization of a Halbach magnet array applied to an axial flux machine (AFM) in a 12-pole, 18-slots yokeless and segmented armature (YASA) topology, evaluated in the torque–speed characteristics diagram. AFMs offer significant advantages in terms of compact design and high torque density compared to other permanent magnet machine topologies. However, noise, vibration, and harshness (NVH) performance is strongly influenced by cogging torque, electromagnetic torque ripple, and tooth forces. While Halbach magnet arrays are well established in high-performance radial flux machines, only limited research has investigated their influence in AFMs. A Halbach array concentrates magnetic flux on one side of the magnet arrangement, leading to increased air gap flux density and a strongly reduced need of a back iron yoke under the magnets. By using a Halbach array, the magnetic field distribution in the air gap becomes more sinusoidal, thereby reducing harmonic components. Previous studies have primarily focused on further torque enhancement or mass reduction through the elimination of back iron. Given that AFMs already exhibit high torque and power density, the objective of this paper is the reduction of NVH factors such as cogging torque, torque ripple amplitudes and tooth forces while minimizing the required magnet mass and maintaining the specified performance criteria. In the optimization process, in addition to the segmentation of the pole and transition magnets, the magnet height as well as the required thickness of the back iron yoke are optimized. For the design and optimization of the Halbach array, two-dimensional (2D) and three-dimensional (3D) finite-element (FE) models are combined with surrogate modeling techniques. In addition to the impact on torque ripple, further potential benefits of the Halbach configuration, including improvements in efficiency and reductions in overall motor weight, are analyzed and discussed.
Müller, KarstenSchulz, FabianBremer, MartinBurkhardt, YvesDe Gersem, Herbert
This specification defines limits of variation for determining acceptability of composition of cast and wrought corrosion and heat-resistant steels and alloys, maraging and other highly alloyed steels, and iron alloy parts and materials acquired from a producer.
AMS F Corrosion and Heat Resistant Alloys Committee
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 primarily controlled by the stacking factor, which statistically characterizes the glue contribution in the axial direction. In contrast, out-of-plane properties (e.g., elastic modulus and shear modulus in the stack direction) are determined jointly by the glue’s axial thickness contribution and its in-plane spatial distribution. To capture these coupled effects, an enhanced homogenization framework is developed using a representative volume element (RVE) formulation implemented through finite element analysis (FEA). The laminated structure is represented as an equivalent orthotropic material, enabling directional stiffness variation induced by nonuniform bonding and lamination material. Parametric simulations establish quantitative relationships between macroscopic core properties and glue configuration, bonding pattern, and stacking factors. A closed-form analytical solution is also derived for simplified cases to support verification. The predicted effective properties show good agreement with experimentally correlated values from production cores, and with analytical solutions under simplified bonding assumptions as well. The proposed methodology enables practical inclusion of glue-disposition effects in early-stage predictive models, thereby improving the fidelity of laminated motor-core NVH assessments and generic structural analysis.
Nie, Zifeng
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
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% Carbon Equivalent (CE), Unalloyed hypereutectic >4.3% CE, Niobium alloyed Eutectic and Niobium alloyed hypereutectic gray cast iron. The results demonstrate the advantages of Niobium alloyed FNC treated discs in reduced wear and meeting Euro7 airborne emission requirements. The Niobium alloyed eutectic Gray Cast Iron plus FNC treatment exhibited the best wear debris performance for both the Non-Asbestos organic (NAO) and Low Metallic (Low Met) friction materials. The Niobium alloyed hypereutectic Gray Iron plus FNC treatment also performed well with both NAO and Low Metallic friction materials.
Barile, BernardoHolly, Mike
This specification covers established manufacturing tolerances applicable to sheet, strip, and plate of corrosion- and heat-resistant steels, iron alloys, titanium, and titanium alloys. These tolerances apply to all conditions, unless otherwise noted. The term “excl” is used to apply only to the higher figure of the specified range.
AMS F Corrosion and Heat Resistant Alloys Committee
This specification covers a corrosion- and heat-resistant iron alloy in the form of welding wire.
AMS F Corrosion and Heat Resistant Alloys Committee
“Big iron” instruments, aka diagnostic radiology equipment such as x-ray, ultrasound, and CT scanners, are indispensable for diagnosing and guiding treatment for an array of conditions from tumors to arthritis to fractures. While a tremendous asset for hospitals, these instruments are traditionally large, heavy, power hungry, and expensive. They are also difficult to acquire, install, and use.
Advanced ferritic nitrocarburizing process combined with a specialized post-oxidation treatment described as FNC + Smart ONC® [1] is developed for brake rotor applications. The process can be applied to standard grey cast iron brake rotors, significantly reducing PM 10 emissions to levels below the Euro 7 limits for most vehicles equipped with at least some recuperative braking capabilities, all without compromising performance. Finished grey iron brake rotors, ferritic nitrocarburized and post oxidized were evaluated according to several industry standards. The standards include SAE J2707B (Block Wear Test including Highway) [2], GRPE-90-24 Rev.1 Emission Test (Full WLTP Brake Cycle 6 Times) [3], and SAE J2522 (AK-Master Performance) [4]. Nitrocarburized post oxidized brake rotors were compared to untreated grey iron rotors exposed to several friction materials. Ferritic nitrocarburizing and post oxidation addresses the issue of corrosion, which is particularly relevant for brake rotors that experience less use in vehicles with recuperative braking systems. Improved corrosion performance of ferritic nitrocarburizing and post oxidation could potentially eliminate the need for the conventional practice of painting rotors. Corrosion performance was validated by conducting cyclic corrosion according to SAE J2334 (Cyclic Corrosion, 36 cycles) [5]. A reduction in brake emissions by 50 percent was achieved for existing vehicles without recuperative braking systems.
Winter, Karl-MichaelHolly, Mike
The rapid development of electric mobility leads to improve the performance of all the powertrain components. There is still a high need to maximize their efficiency for autonomy reasons, but weight and volume are critical parameters for automotive, aeronautic or train applications. This paper focuses on electrical machines, especially the permanent magnet synchronous axial flux motors (PMSAFM) which offer advantages in terms of power density and volumetric electromagnetic torque. The paper proposes a panorama of solutions for designing such a motor, with an application case to 100 kW – 10000 rpm, and an objective of 12 kW/kg at steady state. Obtaining such a power density can be obtained by optimizing the design, by boosting the current, using a high DC voltage, choosing a high-performance electrical steel and adapted permanent magnets, etc). For the PMSAFM topologies several configurations can be considered, and the authors show that a double rotor PMSAFM surface-mounted magnets configuration leads to the best power density. Different cooling technics are described. Then, magnetic materials as FeSi or FeCo steel are analyzed, as well as the impact of the process on the magnetic circuit performance, especially how rolling the laminations can drastically modify the permeability and iron losses. The authors describe the different permanent magnets configurations, and the influence of their segmentation on the losses. The last part is dedicated to the insulated windings, especially those able to work at high temperature, up to 350°C.
Lecointe, Jean-PhilippeHebri, MohamedBauw, GrégoryFawaz, SaraDuchesne, StéphaneZito, GianlucaABDELLI, AbdenourARSLANE, Idir
The multinational EPIIC programme, involving Airbus Defence and Space, is exploring multiple exciting innovations to strengthen Europe's defense capabilities and technological sovereignty. Airbus, Toulouse, France Imagine Tony Stark soaring through the skies in his iconic Iron Man suit, each command answered with a seamless blend of futuristic technology. Now imagine the cockpit of tomorrow's fighter jet.
Imagine Tony Stark soaring through the skies in his iconic Iron Man suit, each command answered with a seamless blend of futuristic technology.
Due to the increasing precision requirements for stainless steel castings in the current industrial field, we take stainless steel as the object, use numerical simulation to analyze the manufacturing process of castings, and explore the mechanism of related defects and preventive measures. The results indicate that in the process optimization of small castings, the maximum shrinkage and porosity of the conventional scheme, the optimization scheme with the addition of cold iron and insulation riser, and the optimization scheme with the improved pouring system combined with the optimal parameters are 1.83%, 1.64%, and 1.42%, respectively. The optimal pouring temperature, pouring speed, and shell preheating temperature of medium- and large-sized castings are: 1620°C, 1.5 kg/s, and 1100°C, respectively. According to the aforementioned findings, the study raises the standard of precision production for stainless steel, and fuel the growth of the precision casting sector.
Huang, JieZhang, Hongshan
Performing highly representative tests of aircraft equipment is a critical feature for gaining utmost confidence on their ability to perform flawlessly in flight under the entire spectrum of operating conditions. This can also contribute to accelerate the certification process of a new equipment. A research project (E-LISA) was performed in recent years, as part of the European funded Clean Sky 2 framework, with the objective of building an innovative facility for testing an electrically actuated landing gear and brake for a small air transport. The project eventually led to the development and construction of an Iron Bird able to reproduce in a realistic and comprehensive way a full variety of landing test cases consistent with certification specifications and landing histories available in the repository of the airframer. The Iron Bird that was eventually developed is a multi-functional intelligent and easy reconfigurable facility integrating hardware and software allowing to perform a full verification and validation of an electrically actuated landing gear and brake over the representative operating conditions, and under normal, degraded and faulty conditions.
De Martin, AndreaBertolino, AntonioJacazio, Giovanni
Researchers from the Disruptive and Sustainable Technologies for Agricultural Precision (DiSTAP) interdisciplinary research group of the Singapore-MIT Alliance for Research and Technology (SMART), MIT’s research enterprise in Singapore, in collaboration with Temasek Life Sciences Laboratory (TLL) and MIT, have developed a groundbreaking near-infrared (NIR) fluorescent nanosensor capable of simultaneously detecting and differentiating between iron forms — Fe(II) and Fe(III) — in living plants.
Gray cast iron is a cost-effective engineering material widely used for heavy duty engine blocks and brake rotor discs in vehicles. Thermomechanical fatigue (TMF) frequently occurs during vehicle operation due to temperature fluctuations in brake rotors. To speed up the design of the component, design structurally sounding brake rotors, and prevent premature thermally induced cracking, it is critical to investigate TMF behavior of the gray cast iron. This study presents a series of fatigue tests, including isothermal low cycle fatigue (LCF) tests at temperatures up to 700°C, as well as in-phase (IP) and out-of-phase (OP) TMF tests across various temperature ranges. Because of the asymmetric behavior in tension and compression, creep behaviors in both tension and compression and oxidation are also studied. These behaviors are the key to enable simulation of thermally induced cracks in rotors.
Liu, YiLee, HeewookHess, DevinCoryell, Jason
The improvement of heat dissipation performance of ventilated brake discs is vital to braking safety. Usually, the technical approaches shall be material optimization or structural improvement. In this paper, a simulation model of the heat transfer of brake discs is established using STAR-CCM+ software. Cast iron, aluminum metal matrix composite (Al-MMC), and carbon-ceramic composite materials (C-SiC) are compared. The results show that: Al-MMC has better thermal conductivity so that a more uniform temperature gradient distribution shall be formed; C-SiC has poorer heat capacity yet, according to previous studies, it has better thermal stability, which is the ability to ensure its friction factor under high-temperature condition; cast iron performs better with convective heat transfer rate, which enhances the heat transfer between the surface and surrounding flow field. Based on the results, this paper proposes four types of material combined brake discs using different friction materials and geometry structures. Al-MMC and C-SiC friction layers are compared at the level of material application. At the level of geometric structure, 3mm and 5mm are chosen to be the thickness, and the different simulations of simulation are discussed. For material selection, the material-combined discs have lower friction surface temperatures compared to the use of single materials, and the overall temperature gradient distribution is more uniform; for the selection of the friction layer thickness, the use of the 3mm composite friction layer scheme, regardless of the Al-MMC or C-SiC, has a lower friction surface temperature than the 5mm friction layer scheme. For different friction layer thicknesses, using a 3mm friction layer has a lower friction surface temperature than 5mm regardless of the materials, and the temperature distribution is more uniform. However, due to the increased cast iron content, the 3mm solution is less lightweight than the 5mm solution. Overall, the material combination approaches can offer a significant performance improvement over the single material discs, which contributes to the safety of automotive braking.
Wang, JiaruiJia, QingZhao, WentaoXia, ChaoYang, Zhigang
As countries around the world attach more importance to carbon emissions and more stringent requirements are put forward for vehicle emissions, hybrid vehicles, which can significantly reduce emissions compared with traditional fuel vehicles, as well as low-viscosity lubricating oil, have become significant trends in the industry. In this article, a total of nine vehicles of 48 V mild-hybrid models and full-hybrid models are tested. Using three kinds of low-viscosity lubricating oil and driving a total of 120,000 km in environments with low temperature, high humidity, high temperature, or high altitude, the engines are then disassembled and scored. The effects of the four extreme environments on the engine starts–stops, ignition advance angle, engine power, state of charge (SOC), acceleration performance, and oil consumption characteristics of hybrid vehicles are studied; the oxidation characteristics and iron content change characteristics of low-viscosity lubricating oil are analyzed; and how lubricating oil protects the engine in durability tests are verified. According to the test results, in the low-temperature environment, for full-hybrid models, the number of engine starts–stops and the running time are significantly increased, while the SOC is generally high. In the high-temperature environment, for full-hybrid models, the ignition advance angle of the engine is reduced, which inhibits the risk of pre-ignition; the characteristics of the SOC are similar to those in the high-humidity and standard-temperature WLTC working conditions; the oxidation rate of lubricating oil has almost no effect on full-hybrid models; for mild-hybrid models, oil is prone to oxidation and decay. In the high-humidity environment, the oil consumption rate deteriorates with the increase in relative humidity under the same load and engine speed, and the accumulation rate of iron content in oil increases compared with that in the high-temperature and high-altitude environments. In the high-altitude environment, with the increase in altitude, the engine power of full-hybrid models decreases at the same engine speed, resulting in a decrease in the engine’s charging efficiency to the battery, so that the battery level could not be relatively stable. The acceleration performance of both hybrid models decreases significantly with an increase in altitude. After the engines are disassembled, it is found out that with the protection of low-viscosity lubricating oil, the wear of engine parts is very small, and the deposit control is good.
Zhu, GezhengtingHu, HuaPan, JinchongLuo, YitaoHua, LunJiao, YanJiang, JiandiShao, HengXu, ZhengxinYan, JingfengWei, GuangyuanZhang, Heng
Wear-resistant, die-cast B390 aluminum represents a relevant material frequently used in the automotive industry. The wear and its relation to the microstructure along with different alloying additives is studied with efforts toward improved performance. Alloying by Sr allows for a lower Fe content helps in mitigating iron needling. This paper addresses wear performance of B390 and Sr-modified B390 alloys, tested against pearlitic cast iron, used for manufacture of piston rings. The wear tests were designed by using an ASTM G99 standardized pin-on-disc protocol at “wet” (motor oil) and “dry” conditions and were performed using a UMT (Bruker) benchtop tester. The polished cross-sections and friction surfaces were studied to identify the microstructural differences and dominating wear mechanisms. Interestingly, the stronger and harder Sr-modified B390 alloys wear more at dry conditions compared to the standard die-cast B390 alloy. This was ascribed to a change in wear mechanisms of the developed friction layer, which had a considerable impact on the observed friction and wear levels, compared to the observed microstructural differences. Also, the presence of thin liquid film under wet testing conditions helped in controlling the material–lubricant interaction and in achieving lower friction levels.
Kancharla, Sai KrishnaJogineedi, RohitSingireddy, Vishal ReddyMirzababaei, SaerehDierks, MikeFilip, Peter
This research introduces a Detailed Digital Fuel Indicator (DDFI) system to enhance fuel monitoring accuracy in automobiles using advanced infrared (IR) sensor technology for precise fuel level detection. The innovative system includes a secondary tank, meticulously calibrated to the volumetric ratio of the primary tank, to ensure consistent and accurate readings. The DDFI system provides real-time data on fuel levels with an impressive accuracy of ±5%, a notable improvement over the traditional methods. Key components of the system include an IR sensor, a programmable integrated circuit (IC), and a secondary tank fabricated from galvanized iron (GI) sheet metal, ensuring durability and reliability in various environmental conditions. The system is designed to be user-friendly, offering an intuitive interface for drivers to monitor fuel levels effortlessly. Additionally, the DDFI system integrates seamlessly with existing vehicle systems, allowing for easy installation and minimal maintenance. The findings signify a significant advancement in fuel management technology, promising efficient vehicle operation, reduced fuel wastage, and an improved overall user experience. This study highlights the potential for further developments in digital fuel monitoring, paving the way for smarter, more efficient automotive technologies.
Mallieswaran, K.Nithya, R.Rajendran, ShurutiArulaalan, M.
Most rechargeable batteries that power portable devices, such as toys, handheld vacuums, and e-bikes, use lithium-ion technology. But these batteries can have short lifetimes and may catch fire when damaged. To address stability and safety issues, researchers reporting in ACS Energy Letters have designed a lithium-sulfur (Li-S) battery that features an improved iron sulfide cathode. One prototype remains highly stable over 300 charge-discharge cycles, and another provides power even after being folded or cut.
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.
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 behavior of modern automobile brake discs under working conditions. A comprehensive performance analysis of gray cast iron and two different composites (silicon carbide-reinforced carbon fiber and silicon carbide-reinforced aluminum) was carried out structurally and thermally to understand their behavior in real-time. The numeric value of each parameter for each material is presented in tabular format to provide a comparative idea of materials’ performances. This paper compares the performance of different brake disk materials under the same real-time conditions. All considered materials were not present in the ansys library, so we have created new material in the ansys library by providing specific material properties.
Bahulekar, AtharvShiralkar, ShaunakJomde, AmitShamkuwar, SonalPatane, PrashantShinde, TarangDandin, Shahbaz
This article investigates the deformation mechanics of cast iron and its implications for notch analysis, particularly in the automotive industry. Cast iron’s extensive use stems from its cost-effectiveness, durability, and adaptability to various mechanical demands. Gray, nodular, and compacted graphite cast irons are the primary types, each offering unique advantages in different applications. The presence of graphite, microcracks, and internal porosity significantly influences cast iron’s stress–strain behavior. Gray and compacted cast iron display an asymmetrical curve, emphasizing low tensile strength and superior compression performance due to graphite flakes and crack closures. Nodular cast iron exhibits a symmetrical curve, indicating balanced mechanical properties under tension and compression. The proposed simplified macrostructural approach, based on monotonic stress–strain, aims to efficiently capture graphite and crack closure effects, enhancing compressive strength and stiffness. By employing the Neuber and Molski–Glinka methods for notch analysis, we assume nominally elastic behavior of notched components. This represents a novel application for gray and compacted cast iron, aiding in predicting material fatigue life, as demonstrated in other materials with asymmetrical behavior.
LaCourt, CameronLee, Yung-LiGu, Randy
The present work highlights the significance of nanocomposite coatings for their ease of processing and applicability in combating corrosion. Ongoing research is dedicated to the development of an effective nanocomposite hydrophobic coating. A hydrophobic nanocomposite coating was deposited on galvanized iron (GI) using a sol-gel route with polymethylsiloxane (PDMS) reinforced with nano-SiO2. Surface morphology and chemical composition analysis, conducted with scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDAX) and Fourier transform infrared spectroscopy (FTIR), revealed the coating’s structural and compositional attributes. The resulting hydrophobic coating exhibits a water contact angle (WCA) of 104.1°, indicating a 30.45% increase compared to bare GI. Subsequent to these characterizations, the adhesion of the coated GI, rated as 4B per ASTM D3359, is followed by commendable resistance to corrosion, as evidenced by electrochemical tests. The corrosion rate for the coated GI sheet is notably low, at 62.78 × 10−3 mpy, underscoring its anti-corrosive efficacy.
Kumar, PrakashRamesh, M.R.Doddamani, Mrityunjay
Hey superhero fans, meet the researchers making real life Iron Man technology possible. In a new study, engineers from Korea and the United States have developed a wearable, stretchy patch that could help to bridge the divide between people and machines — and with benefits for the health of humans around the world.
A commonplace chemical used in water treatment facilities has been repurposed for large-scale energy storage in a new battery design by researchers at the Department of Energy’s Pacific Northwest National Laboratory. The design provides a pathway to a safe, economical, water-based, flow battery made with Earth-abundant materials. It provides another pathway in the quest to incorporate intermittent energy sources such as wind and solar energy into the nation’s electric grid.
Engine operation produces particles that contaminate the lubricating oil and can damage the engine's internal components. This paper presents a model for a three-coil inductive metal particle sensor and verifies the rationality and accuracy of the model by simulating the motion of a single spherical iron particle passing through the sensor. On this basis, the simulation of coupling double particles with different sizes, distances, and shapes is carried out. The study explores the influence of particle motion on the sensor-induced signal under various conditions. The research shows that when two particles pass through the sensor, the induced voltage signal will produce superposition when the distance between the two particles is small. The peak value of the induced voltage is 1-2 times the peak value of the induced voltage of a single particle. As the distance increases, the peak value of the induced voltage initially decreases, then slowly increases, and finally stabilizes. When the double particle signal is superimposed, the enhancement effect of the peak value of the induced voltage gradually increases as the particle diameter decreases. For particles with the same volume but different shapes, the peak value of the induced voltage increases with the increase of the cross-sectional area of the particles.
Chen, SenShen, YitaoQiang, GuiyanZheng, ZhengWang, ZheyuHao, YinHu, Ting
Options for CNVII emission legislation are being widely investigated in a national program organized by China Vehicle Emission Control Center (VECC) since early 2020. It is foreseen that this possibly last legislation in China will have more stringent emission requirements compared to CNVI, including among other changes especially a further reduction of nitrogen oxide (NOx), inclusion of nitrous oxide (N2O) and sub-23 nm particle number (PN). This study investigates the technical feasibility to fulfill a CNVII emission legislation scenario, based on a modified CNVI 8 L engine operating under both cold and hot World Harmonized Transient Cycle (WHTC) and Low Load Cycle (LLC). Methods to address the challenges are discussed and validated, including application of a twin dosing system, electric heater, hybrid concepts of combining Copper (Cu-), Iron (Fe-) and Vanadium (V-) SCR technologies, filters with ultra-high filtration efficiency and optimization of engine calibration and urea dosing strategies. Based on the results, an advanced aftertreatment system is then proposed that can meet the requirements of the discussed CNVII scenario.
Wang, YanChen, ShuyueZhang, JunChen, JunyinLong, LucasGeisselmann, AndreasBender, MichaelTao, ZeminZhu, Minlin
Just as NASA needs to reduce mass on a spacecraft so it can escape Earth’s gravity, automotive manufacturers work to reduce weight to improve vehicle performance. In the case of brake rotors, lighter is better for a vehicle’s acceleration, reliable stopping, and even gas mileage. Orbis Brakes Inc. licensed a NASA-patented technology to accomplish that and more. This revolutionary brake disc design is at least 42 percent lighter than conventional cast iron rotors, with performance comparable to much more expensive carbon-ceramic brakes.
This specification covers electrical iron in the form of bar, sheet, strip, and plate.
AMS E Carbon and Low Alloy Steels Committee
A University of Bristol-led study, published in The Proceedings of the National Academy of Sciences, demonstrates how to make conductive, biodegradable wires from designed proteins. These could be compatible with conventional electronic components made from copper or iron, as well as the biological machinery responsible for generating energy in all living organisms.
Austempered ductile iron (ADI) is an alternative to hardened steel for machined parts with high hardness, ductility, strength and fatigue strength. The optimal cutting parameters to perform turning operation on ADI with PCBN insert are predicted through the response surface methodology (RSM) approach. Design Expert Software was used to design fifteen experiment trials by changing cutting parameters including speed (N) rpm, feed (f) mm/min, and depth of cut (d) mm. The outcomes of the experiments were then examined. The mathematical model determined in the Analysis of Variance (ANOVA) satisfied output responses concerning the input parameters. The optimal turning parameters, N: 1039.11 rpm, f: .5 mm/min and d: 0.0974 mm is revealed the both responses. The confirmation experiment results revealed that the predicted value of responses is better in agreement with experimented responses. The optimal turning parameters recommended to industries application to machine the ADI with significant production.
Velusamy, K.Senthilkumar, K.M.Selvan, T.A.Viswanathan, A.
The ferrous deuteroporphyrin cast Fe alloy and nickel-coated steel were lap welded successfully using the mechanical stir welding process. It was able to weld junctions with full strength and fracture on the base metal side of nickel-coated steel during the welding process, but ferrous alloy and nickel steel could not be welded together. It was proposed that the joining technique and function of the Ni coating be used in the friction stir lap welding of Ni-coated steel and aluminum alloy. The Ni coating improved both the weldability of iron and steel, resulting in the production of a Fe-Ni eutectic structure with a low melting point at the interface of the two materials. It is possible to successfully fuse steel and ferrous metals together.
Sambath, S.Francis Xavier, J.Jayabalakrishnan, D.Suthan, R.Zahir Hussain, M.
One of the most promising applications for the use of hydrogen in vehicles is in the combustion engine. According to the legislation proposal being considered by European Union, hydrogen internal combustion engines (H2ICE) are zero emissions solution. Among the existing solutions, H2ICE is becoming the preferred one on long haul trucks and offroad applications. This is due to the high durability of the powertrain, the lower initial investment when compared to other alternatives, and the possibility of using low purity hydrogen. However, despite the high potential use of hydrogen, because of it is the smallest known chemical element, its use can result in the penetration of hydrogen into metallic materials, with the undesirable effect of embrittlement. This effect occurs mainly when the material surface is exposed to high temperatures and pressures, or under corrosion. By diffusing into the crystal lattice, hydrogen is accumulated in the interstices and crystalline defects, reducing the ductility of the metallic material. Unlike high strength steels, cast irons present graphite that can accommodate diffused hydrogen, delaying the embrittlement effect. The morphology and amount of graphite, as well as the alloying elements and phases present, play a key role in this issue. As shown in a previous work, using a pressurized vessel, cast iron specimens where exposed to an atmosphere of 20% H2 and 80% N2 at 150 bar and 300 °C for 7 days, and hydrogen embrittlement was not verified. In the present work, the effects of hydrogen embrittlement on different cast iron microstructure were evaluated by a qualitative fracture analysis technique. To this purpose, a current density of 16 mA/cm2 was applied for 24 h in electrolytic solution. Hydrogen embrittlement was not verified since the fractures presented in all samples showed river marks, characteristic of brittle fracture, and dimples, characteristic of ductile fracture. This indicates that the hydrogen saturation to generate embrittlement was not reached.
Turola, JéssicaObara, Rafael BrisollaFerrarese, AndréAlbaneze, Aline Fernandade Souza Cabezas, Carlos
Low-carbon equivalent austempered ductile iron (LCE-ADI) exhibits high modulus of elasticity than conventional austempered ductile iron (ADI) due to less graphite content. Austempering parameters of temperature and time significantly influence the mechanical properties of LCE-ADI. In the present work, response of the material to two-step austempering in the range of 350–450°C was studied, and a comparison was made to single-step austempering. Reduction in ferrite cell size, increase in % carbon in carbon-stabilized austenite (CSA) and increase in volume fraction of CSA led to increase in tensile strength (10%) and hardness (20%), in addition to improved toughness (10%).
Maddi, LakshmiprasadDakre, VinayakLikhite, AjayPathak, Shailkumar
The work investigates the effect of different Iron and Manganese contents in ad-hoc cast specimens made from recycled EN AC-43200 alloy. Tensile tests and metallographic analyses coupled with energy dispersive X-ray spectroscopy measurements are carried out to elucidate the interplay between the microstructure and the quasi-static properties of the Aluminium-Silicon alloy under investigation. A strong correlation between the composition and morphology of Fe/Mn -based intermetallic precipitates and tensile properties is demonstrated. Moreover, it is found that specific intermetallic phases are present only for certain, relative and/or absolute contents of Fe and Mn.
Pavesi, AriannaCasari, DanieleMancini, AlessandroBonfanti, AndreaBarella, SilviaD'Errico, FabrizioBertasi, Federico
An EESM (Externally Excited Synchronous Motor) consists of a rotor with wound copper wires. One of its benefits is the ability to control the rotor electromagnetically with the rotor current, which is an advantage over an IPMSM (Internal Permanent Magnet Synchronous Motor). To practically use it and achieve optimal NVH quietness performance, the air- gap shape was redesigned to generate a sinusoidal curved magnetic flux density distribution. This differs from the standard design, in which the air gap has the same circumference as the rotor and stator. There was a significant reduction in the high-order magnetic flux density, which did not affect the torque. In addition, there was a reduction in the excitation force and minimal iron loss. Unlike an IPMSM, which only uses magnets and produces less heat, the copper wires of the EESM rotor generate heat as current flows through them. To maintain power density, it is important to ensure optimal cooling performance. A new cooling structure was developed to compensate for this increase in generated heat. The new cooling structure includes a direct internal oil projection at the rotor hot points and an indirect one at the stator. Finally, as a side effect of the EESM, the high rotation speed causes a large centrifugal force on the rotor wire. The strength reliability was guaranteed using a slot-wedge shape and precision manufacturing. Synchronous control and high-speed, high-precision, as well as high- density layered winding were done to guarantee the manufacturing speed for multipole wire winding.
Fan, XuWada, Hiroki
Phosphating is the most preferred surface treatment process used for auto body sheet panel before painting due to its low-cost, easy production process, good corrosion resistance, and excellent adhesion with subsequent paint layer. There are different phosphating processes used for ferrous metal like zinc phosphating, iron phosphating, di-cationic & tri-cationic phosphating, etc. Among these phosphate coatings, the best corrosion resistance and surface adhesion are achieved by tri-cationic phosphate coatings (zinc-nickel-manganese phosphate). Many new technologies of phosphating are evolving. Key drivers for this evolution are increasing demand for higher corrosion resistance, multi-metal car body processing in same phosphating bath and sustainability initiatives to reduce the carbon footprints. We have evaluated two of these recent technologies. First technology being evaluated is low temperature phosphating in which phosphate bath temperature is reduced by 10°C and second is liquid activation chemicals for phosphating in which liquid phase chemical is used for activation instead of conventionally used chemical in powder form which resulted in increased activation bath life. Characterization of the phosphating layer formed with these technologies on different sheets like cold rolled steel (CRS), galvanized (GI) and galvannealed (GA) steel is done using SEM and EDS techniques [5]. This study shows that there is significance difference in phosphate crystal size and shape formed, and this has a bearing on the surface protective performance of the coating.
Balasubramanian, JayanthanKumar, VinayKirubakaran, MuthiahLalwani, Rahul
The automotive industry is facing a challenge as efficiency improvements are required to address the strict emission norms which in turn requires high performance downsized, lightweight IC engines. The increasing demand for lightweight engine needs high strength to weight ratio materials. To meet high strength to weight ratio, castings are preferable. However due to strength limitations for critical crankshaft applications, it forces to use costly forgings such as micro alloyed forging steel and Martensitic (after heat treatment) forging steel. To reduce the cost impact, high strength Austempered Ductile iron (ADI) casting is developed for crankshaft applications to substitute steel forgings. Austempered Ductile Iron is having an excellent mechanical properties due to aus-ferritic structure. The improved properties of developed ADI Crankshaft over steel forged crankshaft offers additional weight advantage. The ADI Crankshaft was subjected to rig test and meets the fatigue and durability life at the required Factor of Safety.
Yerra, UmamaheswaraGopal, ManishKolhe, Vivek MPalkar, VishalKumbhar, Dipak
In most cases, the properties of a metal are evaluated in their as rolled condition, prior to any work hardening or bake hardening. But in the Automotive World, these steels get work hardened during the forming process and bake hardened in the paint shop. The goal of this paper is to evaluate the variations in the performance of Dual Phase (DP) steels and understand the most optimized method of testing and property generation. This method can then be used to extrapolate to real automotive components. Dual Phase Steels or DP Steels contain a mixture of Ferrite & Martensite from which they derive their name. They are a part of the advanced high strength and ultra-high strength steels steel family according to World Auto Steels. The Ferrite phase, with its iron content contributes to the material displaying an increased level of ductility whilst, the martensitic phase provides the steel with increased mechanical strength. These two properties together enable the steel to be highly desirable in the automotive industry with varying uses from being used as Body Panels to Crash critical components. These two critical part sets of the vehicle are often heavily simulated and tested. Over the course of this paper, we will try to understand the effects of work hardening, also referred to as Pre-Straining and bake hardening on two popularly used DP Steels. DP grade steels, ISC590Y and ISC780Y were used for the study. The aim of the study is to understand the effect of bake hardening, effect varying levels of work hardening and bake hardening on these steels and correlate it to the base data which is used in simulations. It is also important to try and understand the optimum degree of work hardening that might be required to gain the most out of these steels.
Vegi, NischayRagothaman, Balakrishnan
In comparison to aluminum, Compacted Graphite Iron (CGI) iron has superior mechanical properties, enables the use of parent bore running surfaces and fracture split main bearings, and provides advantageous NVH, package size, cost, and manufacturing CO2 profiles. Despite these advantages, aluminum blocks have leveraged density, and therefore weight, differentials to make considerable gains in the small, in-line passenger vehicle sector over the last 30 years. In order to demonstrate the potential benefits of CGI for small, in-line spark-ignition engines, the present study converted the cylinder block of a series production 1.2 litre three-cylinder engine from aluminum to CGI. Leveraging a novel design concept, with the running surface and load path constructed from high-strength CGI and the outer crankcase housing fabricated from durable, lightweight plastic, the assembled cylinder block achieved the same weight as the original aluminum block. NVH analyses showed that the global flexural modes of the CGI cylinder block were 5% higher than aluminum block while the four main bearing cap modes were 18~40% higher, indicating potential NVH advantages for the CGI engine. It is further noted that the design of the CGI cylinder block was constrained by the need to maintain outer dimensions and bore-centers to facilitate engine assembly for durability testing. It is estimated that a clean-sheet design could have enabled a further 5% reduction in the weight of the CGI block. With weight parity, and the successful completion of a 100-hour durability test, CGI has established a new benchmark for small, in-line passenger vehicle engines.
Dawson, SteveFerrarese, AndreMarquard, Ralf
Diamond-Like Carbon (DLC) is a promising engine material for reducing friction and wear on sliding parts. By contrast, MoDTC lubricant additives are known to promote the wear of a-C:H films. However, the mechanism that promotes wear and the formation of tribofilms on DLC parts when in contact with molybdenum-based lubricant additives has not been sufficiently studied. The purpose of this research is to determine the wear promotion mechanism and formation of tribofilm on DLC by lubricant additives by comparing friction and wear properties. We conducted friction and wear tests using a tribometer with DLC (ta-C, ta-C:H, a-C, and a-C:H) blocks, FC250 (cast iron) rings, and oils containing lubricant additives (MoDTC, MoDTP, and Mo without DTC ligand) by observing and analyzing the sliding surfaces of specimens. No wear was observed for any of the DLCs (ta-C, ta-C:H, a-C:H, and a-C) in combination with oils containing MoDTP or Mo without DTC ligands. Oil containing MoDTC revealed low frictional properties for all tested DLCs (ta-C, ta-C:H, a-C:H, and a-C), but arc-shaped wear occurred on a-C:H, which has low hardness and contains hydrogen only in combination with MoDTC-containing oil. In addition, MoO3 was most frequently detected on the worn surface of FC250 in combination with a-C:H and MoDTC-containing oil, whereas Mo carbide was seldom detected by XPS analysis of any worn surface or deposit. These results indicated that the constitution of the DLC and the hydrogen content are the main factors driving wear promotion by MoDTC, while MoO3 is the main factor promoting wear in a-C:H.
Honda, TomomiKasai, MoritsuguMiyake, Koji
Light weight technologies are inevitable in the automotive industry to increase fuel efficiency and meet emission norms. An engine cylinder block is one of the major elements contributing approximately 3-4 % of the automobile weight. Aluminum cylinder block with cast-in liner is almost 40-55 % lighter than a conventional cast iron block [1] and hence the manufacturing processes and challenges associated with them are of high interest. A heterogeneous cast-in liner of gray cast iron in cast aluminum offers a low cost option, but the mechanical bond created between the liner and aluminum interface is prone to gap formation which affects the engine in terms of in-effective heat transfer, distortion and higher blow-by, and thereby high oil consumption & higher emissions. This study aims at reducing this interface bonding gap by in-depth study of critical process parameters involved in manufacturing of cylinder blocks. The study involved a single cylinder petrol engine block manufactured using High Pressure Die Casting (HPDC) process. Using detailed cause and effect analysis, various stages of HPDC like die design, including gating & cooling system were studied & improved using mold flow analysis. Die casting process parameters like die temperature, warm up shots, and biscuit thickness were optimized. Evaluation of bonding gap was carried out using non- destructive techniques like Immersion Ultrasonic Testing & Computed Tomography Testing and a comparative analysis with experimental results of both methods are discussed. Considering initial investment, testing cost, testing time, sensitivity & resolution, a feasible method may be selected for implementation.
D, BalachandarNataraj, Naveenkumar
Electric vehicle battery thermal management based on liquid cooling is the mainstream form of cooling for new energy vehicles. According to energy consumption, the system is divided into active cooling system and passive cooling system. The cooling of battery modules in these two cooling systems is carried out by liquid-cooled plate, which is connected in series in the cooling system. Therefore, the design of the liquid-cooled plate has a great impact on the effect of battery heat dissipation. In this paper, considering the advantages of existing liquid-cooled plates, the author proposed a series-parallel hybrid dc channel liquid-cooled plate structure, taking square lithium iron phosphate battery pack as the research object. Finally, the effects of different inlet flows and temperatures of the liquid-cooled plate on the thermal performance of the liquid-cooled plate were investigated by using single factor analysis. Studies have shown that the liquid-cooled structure can maintain the battery module temperature within the proper temperature range in high temperature environments (40°C).
Zhong, WenLi, MinShangguan, Wenbin
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