Browse Topic: Polymers

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Towards Realistic Stick-Slip Testing: Efficiently Mapping Material Behaviour across a wide Range of Loading Conditions2026-01-0713To be published on 06/20/2026
To minimise noise caused by interior components rubbing against each other, automotive materials are usually tested in advance with the established stick-slip method according to VDA standard 230-206. This procedure is widely used for soft materials, upholstery and plastics. However, it is limited to constant climatic and selected loading conditions. Contrary, in real application, changing climates and dynamic excitations can nevertheless trigger noise issues even in materials rated as suitable in the prior tests. To address this gap, a new test method has been developed that evaluates the stick-slip behaviour of material combinations for a wide range of loading and climatic conditions. Conducted in a climate chamber with a standard stick-slip bench, the procedure applies sinusoidal excitations, dynamic climatic shifts and advanced data analysis. In addition to the usual results the new method also evaluates realistic scenarios such as starting a vehicle in different seasons or sudden
Fritz, Susanne, Strangfeld, Martin
Dynamic characterisation and modelling of Electric Cables under representative load conditions2026-01-0676To be published on 06/20/2026
Electric high voltage (HV) cables are commonly used in automotive applications and very prominently in electrified vehicles. These cables are potential flanking transmission paths for structure-borne sound in a broad frequency range and must therefore be included in the NVH design process. Electrical high voltage cables exhibit non-linear mechanical characteristics, when exposed to significant bending the internal geometry of the cable will change and a curvature dependent bending stiffness will result. The electrical cables envisaged in the current publication feature a helically wound stranded aluminium wire core. This conductive core is covered by, in sequence, a silicone rubber insulation, a braided aluminium wire shield with aluminium foil to minimize electromagnetic interference and a silicone rubber outer sheath. An extensive measurement campaign was carried out to dynamically characterize cable specimen of different lengths and cross sections in terms of multi-degree of freedom
Nijman, Eugene, Buchegger, Blasius, Böhler, Elmar, Zeller, Bernhard, Rejlek, Jan, Faksa, Lukáš, Lukavsky, David
Bridging Simulation And Reality: Incorporating Seal Contact Detachment Into Stick–Slip Prediction2026-01-0714To be published on 06/20/2026
Preventing stick–slip in virtual vehicle development combines virtual displacement data with experimental sliding tests. If the calculated relative displacement at a contact exceeds the distance of two stick–slip impulses, that contact could be a potential noise source. Such risks can be mitigated only by design changes or alternative sealing concepts. Stick–slip tests provide the experimental reference, showing how often a frictional pairing produces impulses over a defined sliding distance. The basis for this assessment is Multibody Dynamics (MBD) simulations, which compute component deformations during virtual drives and derive relative displacements at contact interfaces (e.g. in the sealing gap between body and closure), representing the theoretical sliding distance that enables stick–slip effects. Yet, this combined approach has overlooked a critical factor: the deformability of automotive seals. Due to their elastomeric properties and geometry, seals can elastically follow
Strangfeld, Martin, Fritz, Susanne, Weber, Jens, Rosell, Anneli
Improvement of rCF behaviour through the introduction of NF2026-37-0039To be published on 06/09/2026
The use of recycled carbon fibres (rCF) allows for reduction of emissions impacting energy and resource requirements. A major drawback of using rCF composites is the discontinuous nature of the fibres as this limits the performance and applications. The present investigation aimed to overcome some of these limitations by manufacturing hybrid composites by combining rCF and natural fibres (NF). One of the key observations was a significant change in the failure mode of hybrid samples under various loading scenarios, where the composite did not shatter but rather failed in a controlled manner. Initial results also showed an overall improvement impact properties in comparison to plain rCF. Similar performance was observed in other tests. Research was focused on determining the most effective ply sequencing under different types of loading and understanding the effect of the ply sequence on the failure mechanisms. It was determined that depending on the application, the layups does effect
Hnatyk, Dawid, Chrysanthou, Andreas, De Vuyst, Tom, Ismail, Sikiru
Investigating the Electrochemical Corrosion Behaviour of Bamboo Fiber-Marine Waste Reinforced Polymer Matrix Hybrid Composites for Light Weight Applications2026-26-0733To be published on 06/01/2026
This study investigates the corrosion behaviour of bamboo-crab shell fortified polymer matrix hybrid composites. Three unique hybrid composites were created utilizing the hand layup approach, with epoxy as the matrix material, 15 wt.% bamboo fibers, and varying quantities (3, 6, and 9 wt. %) of crab shell. Electrochemical corrosion tests were utilized to evaluate the hybrid composite's corrosion behaviour. The testing results reveal that epoxy-15 wt.% bamboo-6 wt.% crab shell (P2) composite has better corrosion resistance than epoxy-15 wt.% bamboo-3 wt.% crab shell (P1) and epoxy-15 wt.% bamboo-9 wt.% crab shell (P3). A potentiodynamic polarization test revealed an icorr value roughly five times lower than P1 and three times lower than P3 composites. Furthermore, the Nyquist plot obtained from the EIS study revealed that the P2 composite has a larger capacity loop than the P1 and P3 composites. It also indicates that the P2 composite is more resistant to corrosion than the other two
Senthilkumar, N., Srinivasan, D, G, Perumal, Balakrishnan, Deepanraj
Evaluating Volume and Hardness change in Fluorocarbon and Ethylene Propylene Rubber Elastomers: Effects of Fluid Aging2026-26-0758To be published on 06/01/2026
Abstract: This research paper investigates the performance of FKM (Fluorocarbon) seal material when exposed to a 50:50 ethylene glycol-water mixture. The study aims to determine the volume change percentage and Hardness change of FKM elastomers under standardized testing conditions. The experimental approach follows ASTM D471 and ASTM 2240 guidelines, focusing on weight and hardness measurements of the test samples to establish a success criterion. The results provide critical insights into the chemical compatibility and durability of FKM elastomers in Aerospace and industrial applications where ethylene glycol-water mixtures are commonly used. The findings contribute to enhanced material selection and design considerations for sealing applications subjected to glycol-based fluids. Samples of FKM material were immersed in the fluid at controlled temperatures and durations, simulating real-world operational conditions. The primary metric of interest, volume change percentage and
Yarolkar, Makrand, Patil, Sandip, Singh, Tanul
Advancing Aerospace Interiors: Evaluation of the In-House Polymer Pellet Additive Manufacturing System2026-26-0765To be published on 06/01/2026
The Elektra printer is an open-source, pellet-based (FGF) 3 axis additive manufacturing system developed by Collins in collaboration with Pollen AM to enable large-scale, cost-efficient 3D printing using standard polymer pellets. In alignment with the Make in India program, Elektra represents a significant step toward localized, industrial-scale additive manufacturing that delivers affordability, flexibility, and performance for aerospace and allied industries. The system provides four major advantages. First, it enables cost-effective part production by leveraging standard injection molding grade thermoplastic pellets instead of expensive proprietary feedstocks. Second, its large build volume (800mm*800mm*400mm) supports the manufacture of tools, fixtures, and structural parts often restricted by conventional systems. Third, Elektra is compatible with a broad range of engineering and high-performance polymers that are flame retardant, ensuring adaptability for multiple use cases
Kini, Aditya Deepak, Sundar, Santosh
IMPROVEMENT OF MECHANICAL PROPERTIES OF SYNTHETIC FIBER REINFORCED COMPOSITES THROUGH ADDITION OF GRAPHENE OXIDE2026-26-0753To be published on 06/01/2026
Unmanned Aerial Vehicles (UAVs) demand structural materials that are lightweight, strong, impact-resistant, and durable in diverse environments.The synthetic fiber and natural fiber reinforced polymer composites have varying mechanical performance depending on the fibermatrix interfacial properties. This research analyzes the influence of Graphene Oxide (GO) nano fillers on mechanical properties of composites. Firstly, the epoxy resin was was modified by incorporating different weight percentage of graphene oxide. This resin was used to make an composite laminate using different materials (Carbon, Glass and Natural Fibers). Then the composites were put through the tensile, compression, flexural, and impact strength tests. The synthetic fiber and natural fiber reinforced polymer composites have a significant improvement in mechanical properties due to the addition of graphene oxide.
Manoharan, Dinesh, Langford, Peter, M.K., Padmanabhan, R, Prithviraj, Rajkumar, Subbiah, Karthikeyan, Ravikumar, Veeramuthu, Balasubramaniyan, Gunaseelan, John, T, Thangaraj
Electrical Harnessing in Satellite Launch Vehicles of ISRO – Methods for Sustainable, Safe, and Reliable systems2026-26-0779To be published on 06/01/2026
The electrical harness serves as the "neural network" for satellite launch vehicles, providing the interfaces for all guidance, health monitoring, and control systems during a mission. This system is composed of cables, and connectors. The wires are made of metallic conductors, typically copper plated with silver or gold to enhance conductivity and prevent oxidation. These conductors are insulated with polymeric materials such as PTFE, Kapton, ETFE, or TKT. Connectors, which are the interface points for electrical circuits, consist of gold or nickel-plated copper contacts housed within a shell. A typical launch vehicle contains an extensive network of electrical harnesses, with approximately 4,200 connectors and 110,000 meters of cable, which contributes to about 30% of the vehicle's total weight. The weight is mostly due to the polymeric insulation rather than the conductors. Challenges and Solutions for Sustainable Systems The paper highlights several key issues with current
K S, Nithish, TR, Binny, D S, Praveen Kumar
Mitigation of Assembly-Induced Cracking in Cyclo Olefin Polymer (COP) Optics through Annealing and Step-Torquing Technique2026-26-0764To be published on 06/01/2026
Light Emitting Diode (LEDs) are the main source of light in Aircraft lighting systems and are mounted on a Circuit Board Assembly (CBA). For some applications, Optics are mounted concentric to these LEDs so that light is focused in the required areas. Polymeric optical materials such as Cyclo Olefin Polymer (COP) are adopted as Optics due to their excellent optical clarity, dimensional stability, moldability and weight saving advantages over glass. However, their relatively high notch sensitivity and the presence of residual molding stresses make them prone to crack initiation during mechanical fastening. In this case study, Optic was fastened directly onto the CBA using self-threading fasteners. During its installation, crack formation was consistently observed around self-tapping screw interfaces, raising concerns over reliability, maintainability, and compliance with aerospace durability requirements. A structured Design of Experiments (DOE) was performed to identify root causes and
S, Nikhil, Singh, Abhimanyu Kumar, Katageri, Praveen, SP, Pradeep, Chandra, Praveen
Retrofit Vibration Mitigation of Launch Vehicle Structures Using Thin Viscoelastic Coatings: Acoustic and Modal Study2026-26-0736To be published on 06/01/2026
Acoustic-induced vibrations pose a significant risk to launch vehicle hardware and payload reliability during critical phases such as lift-off and transonic phase. Reducing such vibrations is especially challenging when the hardware has already been fabricated, limiting the possibility of structural redesign. This study demonstrates a practical post-fabrication solution using a thin PC10 viscoelastic polymer coating applied externally to fully assembled hardware. The PC-10 Thermal Protection System (TPS) is a silicone polymer-based filled compound originally developed by VSSC, ISRO for ablative thermal insulation. Its viscoelastic properties make it suitable for energy dissipation under dynamic loads. Comprehensive evaluations were conducted using both acoustic testing at National Aerospace Laboratories (NAL), Bangalore, and Experimental Modal Analysis (EMA) at ISRO before and after coating application. Results show a substantial decrease in structure response from 150Hz to 2000Hz
Avirah, Nohin K, Panda, Ajay Kumar, Shaikh, Altafhusen
Evaluation of Thermal and Thermo-Mechanical Behavior of Ramie Fiber/Delrin Composites for Aircraft Cabin Components2026-26-0754To be published on 06/01/2026
Abstract This study investigates the fabrication and evaluation of Delrin (polyoxymethylene, POM) composites reinforcing 5, 10, 15, and 20 wt.% chopped ramie fiber (RF). The polymer composites were fabricated via injection moulding technique. Glass transition temperature (Tg), thermal conductivity, Vicat softening temperature (VST), heat deflection temperature (HDT), melt flow index (MFI), and coefficient of linear thermal expansion (CLTE) were the various thermo-mechanical and thermal characteristics of the composites that were systematically evaluated as per the ASTM standards. The Delrin matrix's performance was drastically altered by the addition of RF. Within the formulations, the composite with 15 wt.% RF had the best combination of properties: higher VST and HDT values responsible for more dimensional stability at high temperatures, lower CLTE producing lesser thermal expansion, comparatively better thermal conductivity and more heat dissipation. Eventually, there was a moderate
S, Thirumalvalavan, Senthilkumar, N., Selvarasu, S
Assessment of Injection Gate Location effects on Mechanical Performance of Short Fiber Reinforced Plastic Components using Digimat2026-26-0746To be published on 06/01/2026
The mechanical performance of short fiber-reinforced plastic (SFRP) components is highly sensitive to fiber orientation, which is significantly influenced by the injection gate location during the molding process. Traditionally, gate placement decisions are driven by warpage minimization strategies, often overlooking mechanical performance under diverse load cases. This research introduces an automated workflow within Digimat-MS that integrates injection gate optimization into the early design phase, leveraging Integrated Computational Materials Engineering (ICME) principles. The proposed methodology enables engineers to upload either of Marc, Abaqus or Ansys input decks, select a component of interest, assign material cards, and define gate scenarios. A Design of Experiments (DOE) is then executed locally or remotely, allowing Digimat to simulate and evaluate multiple gate configurations. The system aggregates results and identifies optimal gate locations based on the initiation of
Kauthale, Tanmay, Madhavan, Vinay, Soni, Ganesh
Development of Graphene filled Polypropylene Nanocomposite for Aerospace Application2026-26-0739To be published on 06/01/2026
Polypropylene, a commodity plastic, is the semi-crystalline thermoplastic widely used in high volume for general purpose applications. Polypropylene is the macro molecules of soft and weak backbone, which by reinforcement of fillers in different forms such as fiber, spheroids, nanotubes, flakes, etc., can influence its mechanical, thermal, electrical, creep resistance, and flame resistance properties for use in aerospace applications. Currently, polycarbonate and nylon plastics are used in aerospace applications, however, they are expensive compared with polypropylene. In this thesis, efforts are put to study the effect of reinforcement fillers in the properties of polypropylene composite, primarily the mechanical and flammability properties. The matrix element, polypropylene co polymer and reprocessed polypropylene blended in equal ratio, are coupled with the dispersing phases such as graphene, mica, fumed silica, and polydimethylsiloxane polymer. Effect of graphene as reinforcing
Govindaraju, Parthasarathy
Drilling Studies on Sustainable Lightweight Hybrid Polymer Matrix High Performance Nanocomposites2026-26-0732To be published on 06/01/2026
Worldwide, engineers are exploring the possibility of using polymer composites in their quest for lightweight materials. In an effort to create polymer composites that are less harmful to the environment, the use of biodegradable polymers has been investigated in recent years. Injection molding was used to create a biodegradable polymer composite containing 20 wt.% vetiver fibers (VFs) and 2 wt.% nano-silica (nSiO2) obtained from pearl millet. Parts for unmanned aerial vehicles, interior cabin panels, seating structures, and secondary structural components were made of this composite. Desirability analysis was used to examine and optimize machining (drilling) studies that were designed according to Taguchi's design (L9 orthogonal array). Surface roughness (Ra) and delamination factor (DF) were taken as outputs, while spindle speed (SS) ranging from 1000 to 3000 rpm, feed rate (FR) from 15 to 45 mm/min, and drill diameter (DD) from 6 to 10 mm were used as inputs. The developed
Senthilkumar, N.
Fabrication of Ultrathin Polyimide Optical Filter Films2026-99-1711To be published on 05/22/2026
Polyimides are a class of polymers with imide rings in their main chains. They are renowned for their exceptional mechanical properties, high-temperature resistance, low-temperature endurance, and resistance to chemical solvents, which allow for long-term use under harsh medical operating conditions. Consequently, research on polyimide films has garnered widespread attention. In this study, a two-step method was employed to simplify and optimize the preparation process of polyimide. Initially, a polyamic acid (PAA) solution was prepared, and PAA films were fabricated using a spin coater. Subsequently, the films were imidized to obtain polyimide (PI) films. The impact of various parameters, such as spinning speed, layer number, and temperature, on the film-forming properties of polyimide was investigated using the method of controlling variables. The findings indicate that by setting the spin coater parameters to 700 revolutions per minute (r/min) for 90 seconds, followed by a
Huang, Jiehao, Xu, Zihui, Zhao, Kaihong, Lin, Qiting, Hu, Wenzhong, Wang, Liying
Unidirectional Carbon Fiber Tape Epoxy Repair Prepreg, Vacuum Curing Part 5 - Material Specification for Unidirectional Carbon Fiber Tape Epoxy Prepreg for Repair and Film Adhesive for Repair, 120 to 145 °C (250 to 290 °F) CuringAMS6885/5 (Current)5/7/2026
AMS6885/5 is the Material Specification (MS) which defines the requirements of a unidirectional carbon fiber tape epoxy repair prepreg capable of curing under vacuum for repair of carbon fiber reinforced epoxy structures. It also defines the requirements of an epoxy film adhesive to be applied in a co-bonding process with the prepreg for solid laminate and sandwich bonding.
AMS CACRC Commercial Aircraft Composite Repair Committee
Determination of the Fogging Characteristics of Interior Automotive MaterialsJ1756_202604 (Current)5/2/2026
This recommended practice describes two methods for determining the tendency of interior materials used in automobiles and other vehicles to (a) produce a light scattering deposit (fog) on a glass surface, or (b) produce a measurable deposit (mass) on aluminum foil.
Textile and Flexible Plastics Committee
Synthetic Rubber Hot Oil Resistant, High Swell 45 - 55AMS3222J (Current)4/28/2026
This specification covers a synthetic rubber in the form of sheet, strip, tubing, extrusions, and molded shapes. This specification should not be used for molded rings, compression seals, O-ring cords, and molded in place gaskets for aeronautical and aerospace applications without complete consideration of the end use prior to the selection this material.
AMS CE Elastomers Committee
Securing Child Restraint Systems in Motor VehiclesJ1819_202604 (Current)4/13/2026
The scope of this SAE Recommended Practice is to promote compatibility between child restraint systems and vehicle seats and seat belts. Design guidelines are provided to vehicle manufacturers for certain characteristics of seats and seat belts and to child restraint system (CRS) manufacturers for corresponding CRS features so that each can be made more compatible with the other. The CRS accommodation fixture (see Figure 1) is used to represent a CRS to the designers of both the vehicle interior and the CRS for evaluation of each product for compatibility with the other. The features of the accommodation fixture are described as each is used.
Children's Restraint Systems Committee
Plastic Motor Vehicle Safety Glazing - Tolerances and Fabrication DetailsJ1691_202604 (Current)4/13/2026
This SAE Recommended Practice is intended to cover plastic safety glazing for use in motor vehicles and motor vehicle equipment. Nominal specifications for thickness, flatness, curvature, size, and fabrication details are presented principally for the guidance of body engineers and designers. For additional information on plastic safety glazing materials for use in motor vehicles and motor vehicle equipment, please refer to SAE J673.
Glazing Materials Standards Committee
Characterization of a Low-Cost Insulator Substrate for Traction Power Modules2026-01-01194/7/2026
Demand for cost-effective automotive traction inverters requires improved power module packaging. This paper presents a packaging method using an epoxy composite insulator applied directly to the cold plate surface, replacing Direct Bonded Copper (DBC) and Active Metal Brazed (AMB) substrates. This integration removes the substrate-to-cold plate solder interface and eliminates two material layers from the thermal path. The epoxy composite demonstrates a dielectric strength greater than 60 kV/mm. Thermal resistance (junction-to-coolant) measured approximately 0.17 K∙cm2/W. Electrical characterization showed a relative permittivity of 3.9, which is lower than standard ceramics and results in reduced parasitic capacitance. Initial thermal cycling tests indicated no significant degradation in thermal or electrical performance. These results suggest the epoxy composite insulator could be a promising alternative for traction power modules.
Chen, Yu, Mena-Garcia, Javier, Chen, Hao, Xiao, Kewei, Gupta, Man Prakash, Degner, Michael
High Strain Rate Behaviors of Fiber Reinforced Composites in Principal and Off-Axis Directions2026-01-01754/7/2026
Materials can exhibit significantly different mechanical behaviors compared to quasi-static conditions at high strain rates (> 100 s-1). High strain rate tests using setups such as SHPB (Split-Hopkinson Pressure Bar) can provide, in a practicable manner, the stress-strain relations for a material at high strain rates. Such properties are vitally needed for activities such as simulation-driven impact safety design of composite structures deployed in the form of automotive body parts and assembly, and other sub-systems. Although the behaviors of isotropic and ductile materials such as various metallic alloys appear to have been extensively studied and reported in literature, dependence of mechanical properties of fiber-reinforced composites especially in different off-axis directions are extremely difficult to come across. To fill up this void, a detailed experimental study has been carried out on high strain rate mechanical characterization of a laminated orthotropic glass/epoxy
Bawa, Prashant, Deb, Anindya, Barui, Ananya, Zhu, Feng
Tensile and Fatigue Behavior of High Pressure Die Cast AE44 Magnesium Alloy at Elevated Temperatures2026-01-02344/7/2026
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
Machine Learning Modeling for Compressive Property Prediction of Foams2026-01-05124/7/2026
Foam material models for automotive structural analysis typically require tensile and compressive data at multiple strain rates. The testing is costly and may require a long time to complete. For many applications, foams of similar chemistry are used and the foam structural responses, such as stiffness and compression force deflection, are controlled by the foam density. In such cases, Machine Learning (ML) lends itself as an ideal tool to detect the trends in material response based on density and strain rate. In this paper, two sets of polyurethane (PU) foams of different densities were tested at four strain rates ranging from 0.01/s to 100/s. ML models capable of predicting compressive stress-strain response for a range of densities were developed. The models demonstrated good prediction capability for intermediate strain rates at all foam densities and in extrapolating stress-strain curves at higher densities at all strain rates. The strain rate trends for density outside of the
M, Gokula Krishnan, Kavimani, Harish, Muppana, Sai Siddhartha, Savic, Vesna, Chavare, Sudeep, V S, Rajamanickam
Design Optimization and Dimensional Tolerance Improvement of Expanded Polypropylene (EPP) for Enhanced Automotive System Integration2026-01-02484/7/2026
Historically, EPP has required larger dimensional tolerances and much thicker cross-sections than solid plastics produced by injection molding, vacuum forming, and blow molding. This has proved challenging when attempting to incorporate EPP into a wider variety of automotive applications. JSP has developed multiple grades of EPP that achieve tolerances at thinner cross-sections, once considered difficult to attain. These grades expand the potential for automotive applications by combining the established benefits of EPP with improved dimensional precision. This tighter control enables advances in part design and performance, including reduced wall thicknesses, improved surface appearance, reduced weight, lower cost, part consolidation, and more efficient molding with an improved processing window, resulting in faster cycle times and reduced utility consumption. At the vehicle level, these improvements contribute to lighter overall weight for reduced carbon footprint, as well as
Sopher, Steven, Parker, Joshua
Dynamic Characterization and Viscoelastic Modeling of Polymer Foams for Automotive Applications2026-01-02364/7/2026
Viscoelastic behavior of polymeric materials serves as a critical indicator of their internal structure and chemical composition, offering valuable insights into energy absorption and dissipation mechanisms. This study focuses on the dynamic characterization of polymer foams through both experimental and numerical approaches, aiming to accurately capture their time and frequency dependent mechanical response. Experimental investigations include uniaxial tension and uniaxial compression, which characterize hyperelastic or instantaneous behavior of the material. Stress relaxation tests and Dynamic Mechanical Analysis (DMA) characterize the dependence on time and frequency. A combination of these tests is effectively utilized to create viscoelastic material models that can describe the material response as a function of time and frequency containing a viscous and an elastic part. This paper presents dynamic characterization of polymer foams in finite element simulations. Theoretical
M, Gokula Krishnan, Lin, Chunfu, Savic, Vesna
Design Development and Optimization of Hybrid Cross-Car Beam for Performance Here2026-01-05134/7/2026
The cross-car beam (CCB) within the instrument panel (IP) is a multifunctional structural element that supports safety, vibration control and modular integration in automotive design. The reduction of mass without compromising structural integrity plays a vital role in this endeavor. This study presents the design and optimization of design intent model of magnesium beam to meet the performance requirements Vs study model of hybrid cross car beam using magnesium steering column bracket, steel and plastic material to achieve reduced mass and enhanced stiffness while meeting performance targets. Advanced Computer Aided Engineering (CAE) techniques were employed, including topology optimization, lattice optimization, bracket sensitivity studies as well as shape & gauge optimization. Performed benchmarking against industry models such as Tesla Model Y observed hybrid material with structural simplification. The final hybrid beam design demonstrated overall cost reduction, while satisfying
Didgur, Gulzarahmed, McAdams, Ian, Viswaraj, Obuliraj
NASA Tech Briefs: April 202626AERP044/2/2026
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
EP40: Structural Epoxy Used for Steel Bonding in Marine Applications26AERP04_074/1/2026
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. Master Bond Inc., Hackensack, NJ To reduce its environmental impact and pollution, the shipping industry is investigating methods to construct more lightweight ships. One potential method is using adhesive bonding techniques to replace traditional welding and riveted joints on ships to fabricate lighter ships with smaller carbon footprints. However, adhesives age and deteriorate when exposed to moisture, high temperatures, and ultraviolet light. This makes it necessary to understand how they age in maritime environments to determine whether they can truly replace traditional welding techniques. To this end, researchers at Centro de Investigación en Tecnologías Navales e Industriales (CITENI) and Centro de Investigación TIC (CITIC) developed a new
Sheet, Polychlorotrifluoroethylene (PCTFE), Molded, UnplasticizedAMS3646E (Current)3/25/2026
This specification covers a 100% homopolymer of polychlorotrifluoroethylene (PCTFE) in the form of molded sheet 0.250 inch (6.35 mm) and under in nominal thickness.
AMS P Polymeric Materials Committee
Rods, Sheets, and Molded Shapes, Polychlorotrifluoroethylene (PCTFE), UnplasticizedAMS3650E (Current)3/16/2026
This specification covers a 100% homopolymer of polychlorotrifluoroethylene (PCTFE) in the form of rods, sheets, and molded shapes.
AMS P Polymeric Materials Committee
Polychlorotrifluoroethylene (PCTFE), Compression Molded, Heavy Sections, UnplasticizedAMS3645E (Current)3/16/2026
This specification covers a 100% homopolymer of polychlorotrifluoroethylene (PCTFE) in the form of sheet 0.250 inch (6.35 mm) and over in thickness, rod, heavy wall tubing, and large molded and machined parts.
AMS P Polymeric Materials Committee
Test Slabs, Acrylonitrile Butadiene (NBR-H) Medium-High Acrylonitrile, 65 - 75AMS3217/1D (Current)3/13/2026
This specification covers a standard acrylonitrile butadiene (NBR-H) rubber stock with medium-high acrylonitrile content in the form of molded test slabs.
AMS CE Elastomers Committee
Test Standard for Vulcanized Rubber and Thermoplastic Elastomer Determination of Compressive Stress Relaxation (CSR) ResponseJ2979_202603 (Current)3/13/2026
The scope of this document is to define a test method for performing the Compression Stress Relaxation (CSR) Test with the Automotive Standard (ASD) or HP CSR Jig using the appropriate test fixtures, configurations, and procedures. This standard defines the equipment needed, guidelines for running the test, and the format for generating the results and analyzing the data.
Committee on Automotive Rubber Specs
Marking of Rubber PartsJ2332_202603 (Current)3/2/2026
This SAE Recommended Practice provides a system for marking thermoset rubber parts to designate the general type of material from which the part was fabricated.
Committee on Automotive Rubber Specs
Composite Current Collectors and Aramid Separator Enabled Safer High-Nickel Batteries2026-01-70322/27/2026
The requirement on high energy density Li-ion batteries demands high energy chemistry system, this rise concerns on batteries’ safety issue. Battery non-active components, including current collectors and separator play important role in improving battery safety. Composite current collectors, which are consisted of a polymer layer between two plated thin metal layers, are widely treated as a solution to reduce safety concerns caused by high nickel layered cathode materials, e.g. LiNi1-x-yCoxMnyO2, LiNi1-x-yCoxAlyO2 and LiNi1-x-y-zCoxMnyAlzO2 with Ni content higher than 0.8. In the meantime, composite current collectors can reduce most weight of current collectors and improve the cell’s gravimetric energy density without replacing cathode or anode materials. Moreover, high thermal stable separator could effectively prevent internal short circuit for it melts in higher temperature. In this work, we came up with a cell design which contains composite current collectors as positive
Liu, Jingyuan, Lu, Yong, Liu, Haijing
Test Slabs, High Strength, Fluorosilicone (FVMQ) 55 - 65AMS3217/7C (Current)2/20/2026
AMS3217/7C has been declared “STABILIZED” by SAE AMS Committee AMS CE Elastomers and will no longer be subjected to periodic reviews for currency. Users are responsible for verifying references and continued suitability of technical requirements. Newer technology may exist.
AMS CE Elastomers Committee
Effect of Sebastiana Rostrata Fiber Loading on the Tribological Behaviour of Polycaprolactone Biocomposite2026-28-00212/12/2026
This study investigates the tribological behaviour of Sesbania rostrata fiber (SRF) reinforced polycaprolactone (PCL) biocomposites using a pin-on-disc wear couple. The stationary SRF/PCL composite specimen interacted with a rotating EN31 steel disc (64 HRC), establishing the sliding wear interface in accordance with ASTM G99 standards. Composite laminates containing 10, 20, and 30 wt% SRF were evaluated at a sliding velocity of 1 m/s over a fixed distance of 1000 m under varying normal loads. The incorporation of SRF significantly enhanced the wear performance relative to neat PCL, with 20 wt% fiber loading achieving the lowest coefficient of friction and specific wear rate due to improved load transfer, stronger interfacial adhesion, and a more uniform laminate structure. In contrast, the 30 wt% composite exhibited fiber agglomeration, reduced homogeneity, and weakened fiber–matrix interactions, resulting in increased wear. SEM microstructural analysis confirmed the formation of a
Raja, K., Senthil Kumar, M.S.
Modelling and Analysis of Complex Shaped Cracks2026-28-00482/12/2026
This study provides an extensive analysis through finite element analysis (FEA) on the effects of fatigue crack growth in three different materials: Structural steel, Titanium alloy (Ti Grade 2), and printed circuit board (PCB) laminates based on epoxy/aramid. A simulation of the materials was created using ANSYS Workbench with static and cyclic loading to examine how the materials were expected to fail. The method was based on LEFM and made use of the Maximum Circumferential Stress Criterion to predict where cracks would happen and how they would progress. Normalizing SIFs while a crack was under mixed loading conditions was achieved using the EDI method [84]. We used Paris Law to model fatigue crack growth using constants (C and m) for the materials from previous studies and/or tests. For example, in the case of titanium Grade 2, we found Paris Law constants with C values from 1.8 × 10-10 to 7.9 × 10-12 m/cycle and m values from 2.4 to 4.3, which illustrate differing effects of their
T, Lokesh, Bhaskara Rao, Lokavarapu
Vibrational Analysis of Hybrid Composite Laminated Plates of E – Glass and Areca Fibers with Brake Pad Waste Powder2026-28-00732/12/2026
This study focuses on the vibration analysis of hybrid composite laminated plates fabricated from E-glass Fiber and areca Fiber reinforced with epoxy resin. The hybrid laminates were prepared using the Vacuum Assisted Resin Transfer Moulding (VARTM) process with different stacking sequences and Fiber ratios, where brake lining powder was also incorporated as a filler in selected configurations to enhance mechanical and damping properties. The fabricated plates (280 × 280 mm) were subjected to experimental modal analysis using an impact hammer and accelerometer setup, with data acquisition carried out through DEWESoft software. Natural frequencies and damping ratios were determined under three boundary conditions (C- C-C-C, C-F-C-F, and C-F-F-F). The results revealed that Plate 1, with E-glass outer layers, areca reinforcement, and filler addition, exhibited the best vibration performance, achieving a maximum natural frequency of 332.8 Hz under C-C-C-C condition, while Plate 2 showed a
D R, Rajkumar, O, Vivin Lenin, R, Saktheevel, R G, Ajay Krishna, Ng, Bhavan
Genetic Algorithm Based Optimization of Chaboche Kinematic Hardening Parameters along with the Validation of FE Model through Characterized Crack Initiation2026-28-00862/12/2026
In the context of electro-mobility for commercial vehicles, the failure analysis of a connector panel in a DCDC converter is crucial, particularly regarding crack initiation at the interface of busbar and plastic component. This analysis requires a thorough understanding of thermo-mechanical behavior under thermal cyclic loads, necessitating kinematic hardening material modeling to account for the Bauschinger effect. As low cycle fatigue (LCF) test data is not available for glass fiber reinforced polyamide based thermoplastic composite (PA66GF), we have adopted a novel approach of determining non-linear Chaboche Non-Linear Kinematic Hardening (NLK) model parameters from monotonic uniaxial temperature dependent tensile test data of PA66GF. In this proposed work a detailed discussion has been presented on manual calibration and Genetic Algorithm (GA) based optimization of Chaboche parameters. Due to lack of fiber orientation dependent test data for PA66GF, here von Mises yield criteria
Basu, Parichay, Srinivasappa, Naveen
Next Generation Carbon Fiber Composites 3D Printer for Hypersonic Research26AERP02_082/1/2026
Auburn University's Applied Research Institute in Huntsville is adding some serious fiber to its diet. Auburn University, Auburn, AL In collaboration with Auburn University's Center for Polymers and Advanced Composites (CPAC) and the Department of Aerospace Engineering, the institute recently acquired a CF3D Enterprise Cell - a next-generation 3D carbon fiber composites printer set to define the future of the nation's hypersonic programs. Developed by Idaho-based Continuous Composites, the CF3D system represents a highly specialized advanced manufacturing capability and is the only system of its kind currently operating in Alabama.
Sensorless Tire Health Monitoring System based on Machine Learning for Passenger Vehicles2026-26-06701/16/2026
Tire wear progression is a nonlinear and multi-factor degradation phenomenon that directly influences vehicle safety, handling stability, braking performance, rolling resistance, and fleet operational cost. Global accident investigations indicate that accelerated or undetected tread depletion contributes to nearly 30% of highway tire blowouts, highlighting the limitations of conventional wear indicators such as physical tread wear bars, mileage-based service intervals, and periodic manual inspections. These manual and threshold-based approaches fail to capture dynamic driving loads, compound ageing, pressure imbalance effects, or platform-specific wear behaviours, thereby preventing timely intervention in real-world conditions. This work presents an Indirect Tire Wear Health Monitoring System that employs an advanced Machine Learning + Transfer learning architecture to infer tread wear level and Remaining Useful Life (RUL) without relying on any tire-mounted sensors. The system ingests
Imteyaz, Shahma, Iqbal, Shoaib
Material-Optimization in Rib-Stiffened Polymer Structures: A Computational & Analytical Study2026-26-04981/16/2026
The demand for lightweight yet rigid polymer components continue to drive innovation in structural design, particularly for applications requiring optimal stiffness-to-weight ratios. The current literature focuses on single ribbed or homogeneous plate behavior. Understanding the behavior in parallel rib arrangement with inter connections – especially when the ribs are spaced close together is yet to be done. This study examines an alternative rib-stiffening approach for polypropylene plates, where conventional single-rib geometries are reconsidered in favor of parallel dual-rib configurations. While single ribs have been extensively studied, the potential benefits of distributed rib architecture remain less explored, particularly regarding their combined bending performance. The study attempts to understand the behavior of Polypropylene plates specifically, their bending stiffness, load transfer enhancement of the cross-rib structure through mathematical and computational methods. The
Sreejith, M P, Jain, Deepak, Ravi, Abhikrishna, Maheshwari, Pankaj, Kumar, Mandeep
Failure Prevention of Permanent Deformation in HNBR Elastomeric Diaphragms Used in CNG Valve Applications2026-26-02941/16/2026
Hydrogenated nitrile butadiene rubbers (HNBR) and their derivatives have gained significant importance in automotive compressed natural gas (CNG) valve applications. In one of the four-wheelers, CNG valve application, HNBR elastomeric diaphragms are being used for their excellent sealing and pressure regulation properties. The HNBR elastomeric diaphragm was developed to sustain CNG higher pressure However, it was found permanently deformed under lower pressures. In this research work, number of experiments was carried out to find out the primary root cause of diaphragm permanent deformation and to prevent the failure for safe usage of the CNG gas. HNBR diaphragm deformation investigation was carried out using advanced qualitative and quantitative analysis methods such as Soxhlet Extraction Column, Fourier Transform Infrared Spectroscopy (FTIR), Differential Scanning Calorimetry (DSC), Optical Microscopy (OM), Scanning Electron Microscopy (SEM), and Thermogravimetric Analysis (TGA). For
Patil, Bhushan Gulab, NAIKWADI, AMOL, Mali, Manoj, Tata, Srikanth
Numerical Investigation on Thermo-Mechanical Characteristics of Injection-Molded Thermoplastics using Anisotropic Material Properties2026-26-02801/16/2026
This paper presents a comprehensive numerical methodology for simulating the coupled process-structure behavior of short glass fiber-reinforced, injection-molded thermoplastics. The approach integrates elastoplastic and anisotropic material characteristics using three engineering tools: Moldflow, Digimat, and ABAQUS. It accounts for fiber orientation and injection molding defects, linking to thermo-mechanical performance. This method enables accurate virtual modeling of real-time injection-molded components by transferring anisotropic data from Moldflow to ABAQUS. In this study, short fiber orientation and potential injection molding defects such as weld lines and residual stresses are discussed using Moldflow simulation. Besides, Digimat is employed as an interface tool to facilitate the transfer of Moldflow simulation results, namely fiber orientation and material behavior in the allied configurations directly into ABAQUS. This integration enables the evaluation of thermo-mechanical
T, Kalinga, Yanamadala, Dharma Teja, Mattupalli, Venkata, Chirravuri, Bhaskara, Miller, Ronald
Development of Advanced Thermoplastic Elastomeric Mat and Its Study on Thermal Performance of Wireless Charger System2026-26-02831/16/2026
This study aimed to develop a thermally conductive TPE mat and assess its performance in comparison to an existing antiskid rubber mat, specifically evaluating its impact on wireless charger efficiency. Moreover, morphological and thermal analyses were conducted to establish a correlation between the material behaviours of the new and current thermally conductive antiskid mats. The process of developing the thermally conductive TPE involved utilizing a two-roll mill followed by compression moulding to achieve a 2D sheet shape. Notably, the thermally conductive mat demonstrated a consistent enhancement in charging efficiency over the conventional antiskid mat. To examine the thermal characteristics, thermal characterization techniques including DSC and TGA were employed for both the existing and newly developed mats. FTIR spectroscopy was also utilized to confirm the presence of organic functional groups within the mat. The morphological analysis of the fillers used to enhance thermal
Naikwadi, Amol Tarachand, Mali, Manoj, Patil, Bhushan, Tata, Srikanth
Reliability of Rubber Grommets by Stochastic Analysis of Geometric Tolerances2026-26-05011/16/2026
Manufacturing tolerances play a critical role in the quality and functionality of components, particularly those made from rubber. Even slight deviations in dimensions can cause significant issues such as improper fit and reduced performance, leading to increased costs and project delays. This is especially true for rubber grommets, which are nonlinear elastic components commonly used as sealants, gaskets, and insulation covers in automotive and industrial applications. Typically manufactured from EPDM rubber with varying Shore hardness, grommets must maintain precise geometry to ensure sealing integrity and protect adjacent parts. Dimensional inaccuracies can result in failures such as buckling or misalignment, compromising both functionality and durability. This study proposes a digital simulation methodology for early-stage evaluation of grommet robustness, reducing reliance on physical prototypes. Using a stochastic design of experiments (DOE) approach, the influence of critical
Beesetti, Siva, Hattarke, Mallikarjun, James Aricatt, John, Pathan, Eram
Optimizing Stick Slip Performance in Automotive Interiors by Material Selection, Additives and Design Strategies2026-26-03251/16/2026
The automotive industry is highly competitive, especially in terms of design and perceived quality. The use of hard plastics with a high gloss finish is driven by styling trends and the push towards zero gaps, making interfaces critical. In-cabin mood lighting is another feature being offered as a theme for interiors. Dashboard or cockpit designs often incorporate a significant amount of polycarbonate-acrylonitrile butadiene styrene (PC-ABS) and polycarbonate (PC). These materials provide strength and design flexibility but have the disadvantage of material incompatibility when used together, leading to stick-slip phenomena. Traditionally, felt tapes were used as interface isolation to solve this problem, but this increased manufacturing costs and assembly complications. The study focuses on the stick-slip phenomenon and material interface modifications. Specifically, it examines selecting the right surface finish on one side of the PC & PC-ABS interface to change adhesion and friction
Mohammed, Riyazuddin, R, Prasath, Rahman, Shafeeq
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