The car body consists of many parts, between which there are cavities and gaps that water, dust, and noise can enter. To prevent corrosion and reduce noise, these gaps are sealed with a paste featuring complex non-Newtonian properties. Sealing also serves a cosmetic function for visible areas, which demands high quality for better customer satisfaction. Usually, bead length can reach several meters with a height of 0.5-5 mm and a width of 5-40 mm. In this situation, optimizing the robotic paths and sealant flow can speed up production and reduce costs. Accurate and fast CFD modeling helps with planning the sealing process, shortening vehicle development cycles and minimizing costs. Due to the complexity of vehicle body geometry, arbitrary robotic movements, sealing bead length, free surface, and the complex rheological material properties, traditional CFD simulations have difficulties in modelling this process. This paper presents a new framework for modelling the sealing processes

Panov, Dmitrii Olegovich, Zhu, Huaxiang, Basic, Josip, Zhang, Lingran, Kotian, Akhilesh, Menon, Muraleekrishnan, Borra, Ravi Kanth, Ando, Yuya

Novel Air System for 300 kW Heavy Duty Fuel Cell

2026-01-0434

4/7/2026

Hydrogen fuel cell powered vehicles for heavy duty trucking are a promising path for reducing future vehicle emissions due to their reduced mass for storage and faster refueling compared to battery electric trucks. These benefits come at the cost of increased system complexity stemming from the fact that fuel cells generate electricity through a chemical reaction which must be tightly controlled. The air handling system delivers the proper amount of air (oxygen) to react with fuel (hydrogen) in the fuel cell to produce power. Air delivery requires significant power and is the largest parasitic loss for a 300 kW fuel cell. Today’s systems use an electric motor driving an air compressor to supply pressurized air to the fuel cell stack. By operating at elevated pressure levels, fuel cells can achieve higher power density, which is important for vehicle powertrains. In addition to parasitic power loss, hydrogen fuel cell systems often have reliability issues associated with the air

Reich, Evan, Swartzlander, Matthew, Wine, Jonathan, McCarthy, Jr., James, Miller, Eric, Akhtar, Saad, Reddy, Sharan, Lawy, TJ

Design Optimization and Dimensional Tolerance Improvement of Expanded Polypropylene (EPP) for Enhanced Automotive System Integration

2026-01-0248

4/7/2026

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

Development of a Tire Blowout Experimental Platform for Dynamics and Control Validation

2026-01-0202

4/7/2026

Tires are critical to vehicle dynamics, transmitting traction, braking, and cornering forces to the road. A tire blowout, the sudden and rapid loss of inflation pressure due to puncture or structural failure, can cause severe instability, rollover, or collisions. Understanding vehicle response during blowout events is essential for developing robust safety systems and control strategies. Earlier developed simulation models are used to study and understand vehicle behavior during blowouts, but there is a lack of on-road testing platforms to validate these models experimentally. In this paper, an experimental platform integrating a tire blowout device and an instrumentation system has been developed to address this gap. The blowout device consists of multiple solenoid valves mounted on the wheel surface and powered by a 12V power supply. All valves can be triggered at the same time using an RF remote, producing rapid and synchronized deflation. As an extension of this implementation, an

Kanthala, Maha Vishnu Vardhan Reddy, Krishnakumar, Ashwin, Lin, Wen-Chiao, Chen, Yan

Effect of Renewable Fuel Blends on Particulate Emissions in Warm-Up Conditions in a GDI Engine

2026-01-0304

4/7/2026

Renewable gasoline offers significant benefits in reducing greenhouse gas (GHG) emissions. In this study, five gasolines with different renewable hydrocarbon classes and varying distillation curves were taken to investigate their effect on particle number (PN) emissions in a spark-ignition GDI engine at 10 bar indicated mean effective pressure (IMEP) and 2000 rpm. The engine coolant temperature was varied from 90°C to 35°C to investigate the effect of fuel evaporation on soot formation. Injectors with various spray plume targets and start of injection (SOI) timing (300° and 260° bTDC) were used to assess how different gasolines affect engine performance and to determine engine calibration requirements. A simplified transient cycle examines how engine motoring influences PN emissions for test gasolines. A high-speed camera and endoscope were used to identify the sources of soot during fuel combustion. Simulations were done to assess the quality of fuel-air mixing in support of the

Muniappan, Krishnamoorthi, Dahlander, Petter, Helmantel, Ayolt, Alemahdi, Nika, Lehto, Kalle

From Reactive to Proactive: Applying Data Analysis and Automation to Mitigate PLC Communication Disruptions

2026-01-0250

4/7/2026

PLCs (Programmable Logic Controllers) are critical devices in manufacturing, enabling the functioning of machinery and the transmission of build data to other systems in a production facility. Thus, maintaining uptime of these devices is crucial for ensuring that a facility can keep its line running, as even a few minutes of downtime can cost a company thousands in lost units and revenue. One particular pain point that causes downtime is broken communication between the devices and downstream applications, especially those that track orders and traceability. While advances in computing and digital technology have enabled the quick detection of lost signaling and the quick restoration of communication channels, there is much work left to be done in this realm. Besides causing downtime, an incident disrupts the flow of the line, leading to significant effort to restore normal production flow, even after resolution of the incident. In addition, the outage and the post-incident recovery

Jan, Jonathan, Preston, Joshua

Multi-Stage Packaging and Routing Optimization for Automotive Component Layout, Wire Harness and Duct Route Design

2026-01-0507

4/7/2026

Modern vehicle design involves complex considerations and tradeoffs between system integration and layout which have a direct impact on performance, efficiency, and cost. The placement of equipment including control boards, motors, and fans as well as the routing of ducts and wire harnesses poses a time-consuming and intricate problem for design engineers. This paper presents an automated methodology to determine the optimal component packaging configuration, duct routing, and wire harnessing layout to maximize component packing density and minimize the total routing length. A two-stage optimization framework has been developed where the first stage packages the components within the design space with considerations for space utilization, component overlap, proximity relationships, point-to-point accessibility, and component mounting. The second stage implements a custom A* path-finding algorithm and gradient based optimization to determine the optimal route layout between port points

LeFrancois, Richard, Kim, Il Yong

Experimental Study on Macroscopic Characteristics of Ammonia Spray under Flash Boiling and Non-Flash Boiling Conditions with Large-Diameter Single-Hole Nozzles

2026-01-0339

4/7/2026

Ammonia is regarded as a potential alternative fuel, and its spray characteristics are crucial for efficient combustion in engines. For large-bore engines suitable for heavy-duty vehicles or ships, the adoption of large-diameter nozzles is expected to ensure an appropriate fuel flow rate while improving fuel-air mixing efficiency, thereby enhancing in-cylinder combustion performance. This paper conducted an experimental study on the characteristics of liquid ammonia sprays under wide thermodynamic conditions, a wide range of injection pressures, and a wide range of nozzle diameters. The study found that at room temperature, as the ambient pressure increases from 0.1 MPa to 4 MPa, the development of spray penetration slows down. However, at 0.05 MPa, the radial expansion of the near-field spray is greater, and the penetration is slightly behind that at 0.1 MPa. The liquid penetration increases with the increase in ambient temperature. This was because the increase in temperature reduced

Liu, Yi, Zhong, Jie, Hu, Yuchen, Zhu, Wuzhe, Yunliang, Qi, Qingchu, Chen, Wang, Zhi

Life of a Formula One Power Unit: Valvetrain Systems

2026-01-0269

4/7/2026

The world of Formula One (F1) is changing with impending 2026 F1 regulations imposing even stricter limits on engine component usage while increasing races. The valvetrain system, specifically the intake valves, is a critical determinant in controlling gas exchange within the cylinders, directly impacting air-fuel charge and power output. The aim of this investigation is to study the mechanisms of intake valve and valve seat wear which will influence engine performance due to leakage path development. The wear mechanism of the intake valves considers wear from impact from valve seat interaction, sliding and foreign particle abrasion for quantifying valve seat recession. An FIA 2026-2030 regulations compliant valve train model was developed in GT-Suite to help estimate valve seat wear. The validated model could predict valve recession for a given engine operating speed trace from racetrack data. This report presents a systematic methodology for developing valve seat wear quantification

Soh, Sean Kendrick, Samuel, Stephen

The Golden Tester

2026-01-0092

4/7/2026

The objective of this paper is to understand the effort required to integrate the hardware and software of in-vehicle cybersecurity systems. The in-vehicle cybersecurity method discussed is the SAE J1939-91C, which involves Network formation, Rekeying, and secure Message Exchange between Electronic Control Units (ECUs). The SAE J1939-91C network security protocol operates over a CAN-FD network to perform necessary cryptographic operations and key generation. To evaluate the method, test vectors were created to validate SAE J1939-91C key generations and cryptographic operations on the simulated ECU in-vehicle network system hardware (such as the Beacon or Pi devices). We introduce a lightweight, transport-agnostic benchmark comprising deterministic AES-CMAC test vectors and a simple verification utility, requiring no specialized hardware or build system. This minimal artifact set enables reproducible and machine-parsable validation of SAE J1939-91C security across diverse lab

Zachos, Mark, Medam, Krishna Teja

Experimental Validation of a Multi-Row Tapered Roller Bearing Analytical Model for Relating Preload to Frequency Response Characteristics

2026-01-0008

4/7/2026

Roller bearings are used in many rotating power transmission systems in the automotive industry. During the assembly process of the power transmission system, some types of roller bearings (e.g., tapered roller bearings) require a compressive preload force. Those bearings' rolling resistance and lifespan strongly depend on the preload set during the installation process. Therefore, accurate setting of the preload can improve bearing efficiency, increase bearing lifespan and reduce maintenance costs over the life of the vehicle. A new method for bearing preload measurement has shown potential for both high accuracy and fast cycle time using the frequency response characteristics of the power transmission system. An open problem is experimental validation of the multi-row tapered roller bearing analytical model. After validation, the analytical model can be used to predict the assembled system damped natural frequency for a desired bearing preload. This work presents the experimental

Gruzwalski, David, Mynderse, James

Efficient Embedded Control of Nonlinear Systems for Software-Defined Vehicles

2026-01-0075

4/7/2026

Software-defined vehicles (SDVs) are reshaping automotive control architectures by shifting intelligence to embedded systems, where computational efficiency is paramount. This paper presents a systematic evaluation of control strategies (PID, LQR, MPC) for the classical control problem involving inverted pendulum on a cart under strict embedded constraints representative of software-defined vehicle ECUs. The objective is to evaluate and compare the performance of advanced control algorithms under varying control objectives when deployed on microcontrollers with constrained computational and memory resources, representative of the limitations encountered in embedded platforms used for SDVs. Furthermore, the study illustrates systematic optimization strategies that enable these algorithms to achieve real-time execution within such resource-constrained environments. Each control strategy is implemented with careful consideration of algorithmic complexity, real-time responsiveness, and

Vupparige, Varun, Pandya, Vidit

CAE Acceleration with Machine Learning for Results Prediction

2026-01-0488

4/7/2026

Industries are following a tedious product development cycle for developing their product. In product development major steps includes design ideas, Drawings, CAD, CAE, Testing and design improvement cycle. This is a monotonous process and takes time which impacts on its time to deliver product and cost on development. Now a days industries are fast growing and targeting to reduce development cycle time and cost. AI&ML is impacting almost all areas in the industry and significantly reducing efforts time and cost. To make use of AI&ML in CAE, Altair Physics AI is an effective tool. To ensure the design of product traditional way is to develop a CAD of the product, develop, perform CAE and analyze performance. If we consider CAE procedure it is time consuming process which includes FEA model build, applying boundary conditions, running simulation and analyzing results which could take minutes to hours. By using ML with Physics AI we can make predictions on new design of the product in

Dangare, Anand Manohar, Kulkarni, Mandar

Innovation Powered by High-Fidelity Multiphysics Modeling: A Holistic System Optimization of BorgWarner’s Next Generation Integrated Drive Modules

2026-01-0497

4/7/2026

In the stringent market of BEV, the development of integrated Drive Modules (iDM) fitting environmental and customer needs is mandatory. It is important to extract the best from the less. To achieve those goals, a deep insight into complex multiphysics phenomena occurring in an iDM has been achieved by accurate and validated models. This engineering methodology is applied through the development of BorgWarner products, comprising non-exhaustively iDM 180-HF, Externally Excited Synchronous Machine and Multi-Level Inverter. The paper will review the methodology development for deeper understanding involving in-house technical excellence and complemented by strategic partnerships with academic institutions and start-ups. It will present the approach of integrating advanced multiphysics models with high-quality experimental validations, specifically on loss evaluation on electrical machines and inverters. Complex models involving multiphysics such as thermal/fluid coupling or electric

Leblay, Arnaud, Bourniche, Eric, Bossi, Adrien, David, Pascal, Nanjundaswamy, Harsha

Elucidation of Flow Mechanisms Modulating Vehicle Wind Noise by Using Large-Scale CFD Simulation

2026-01-0614

4/7/2026

In vehicle development, noise reduction is critical for ensuring passenger comfort. As electric vehicles become prevalent and engine noise is minimized, wind noise becomes more noticeable. Modulated wind noise, which causes a sense of fluctuation due to atmospheric turbulence, wind gusts, and preceding vehicle wakes, can cause significant discomfort. This noise is characterized as a high frequency sound above 1 kHz, modulated at low frequencies owing to the wind velocity and direction fluctuating at several Hz. The mechanisms behind wind noise modulation are not fully understood, and no established countermeasures have been developed. This is because wind noise perceived through the side window is primarily caused by the A-pillar vortex and door mirror wake, which coexist as complex turbulent flows around the vehicle. Therefore, identifying the source of modulated wind noise around vehicles under fluctuating wind conditions is difficult. This study aims to identify the source of the

Tajima, Atsushi, Hirata, Takumi, Ikeda, Jun, Kamiwaki, Takahiro, Wakamatsu, Junichi, Tsubokura, Makoto

Bearing Fault Diagnosis Method Based on Optimized Variational Mode Decomposition and Deep Temporal Fusion

2026-01-0158

4/7/2026

In the current field of rolling bearing fault diagnosis, two critical challenges persist. First, it is difficult to effectively extract fault features from nonlinear and non-stationary vibration signals. Second, precise diagnosis remains a challenge, especially when distinguishing between different fault types and capturing incipient faults with weak characteristic information. To address these issues, this paper proposes a novel fault diagnosis method based on adaptively optimized variational mode decomposition (VMD) and deep temporal fusion. First, the method improves the traditional sparrow search algorithm (SSA). It enhances SSA’s global optimization capability through strategies like chaotic population initialization and adaptive perturbation. This improved SSA enables efficient global optimization of VMD’s key parameters. Leveraging these optimized parameters, the method decomposes modal signal components with different center frequencies from the vibration signal. This process

Wen, Chao, Zhong, Hong, Wang, Liangmo, Chen, Yong, Gao, Qiang, Li, Yong

A Helical Compression Spring Fracture under Impact Velocity in Pump Operation by Theoretical Study and FEA

2026-01-0271

4/7/2026

Helical compression springs have been used widely in various industries from automotive, aerospace and construction to electronics and medical devices. In the automotive industry, they appear in many places such as suspension, valvetrain, etc., as well in the discharge check valve of Gasoline Direct Injection (GDI) pump, which is the subject of study due to a recent fracture in lab testing. A theoretical study is conducted first to establish the equation governing spring dynamic motion under impact velocity, which can be in high magnitude with surging shock wave along spring axis. A new spring shock wave equation is developed for spring axial motion coupled with coil torsional effect. This newly derived shock wave equation has a broader term than the classic spring formula found in most engineering books. In this paper, it shows that the classic spring shock wave equation is only a special case for the general wave equation newly discovered. Then, a theoretical formula on spring shock

Pang, Michael L., Gunturu, Srinu, Norkin, Eugene

A Vehicle-Integrated Validation Method for Weather-Strip Sealing Performance in Automotive Closure Systems

2026-01-0200

4/7/2026

Weather-strip sealing systems are critical to automotive closure performance, influencing water- and dust-tightness, aerodynamic noise control, and overall NVH quality. Conventional validation often relies on flat or straight JIG-based tests that inadequately represent the curved, angled, and non-uniform geometries of real closures such as doors, tailgates, hoods, roofs, and fixed or movable glass. This disparity limits the predictive accuracy of sealing performance in actual vehicles. This study proposes a vehicle-integrated validation framework that mirrors true geometric and contact conditions. The methodology combines finite element analysis (FEA) of both flat JIG and full-vehicle CAD geometries with experimental JIG tests, establishing a baseline for pressure distribution, compression load, and sealing contact behavior. A comparative analysis highlights significant deviations between flat-section predictions and vehicle-specific closure profiles. Results demonstrate that the

Ganesan, Karthikeyan, Seok, Sang Ho

Accelerometer Location Study for Non-Intrusive Start of Combustion (SOC) Detection in Compression-Ignition Engines

2026-01-0288

4/7/2026

This study investigates the impact of sensor location on accelerometer-based sensing of combustion phasing for compression-ignition engines. Ten accelerometer locations were studied on a light-duty compression-ignition engine for a set of conditions with variations in engine load, speed, injection timing, and injection strategy. Start of combustion (SOC) was identified from the filtered acceleration signal using a previously developed approach. Each location was assessed using both signal-based metrics, including magnitude squared coherence (MSC) between block surface acceleration and in-cylinder pressure, as well as SOC outcome-based metrics, such as detection success rate. Results demonstrate that the mounting location has a significant impact on the ability to extract combustion phasing information from the accelerometer signal. Sensors mounted on the front face of the engine produced the strongest signals for an individual cylinder. For multi-cylinder sensing, side-mounted

Hegge, Graydon, Hanson, Reed, Kim, Kenneth, Rothamer, David

Optimization of Lightweight Gear Blanks to Improve NVH for an Electric Drive Unit

2026-01-0001

4/7/2026

A single-speed electric drive unit (eDU) with multi-stage reduction can have high gear whine due to high pitch-line velocity in the absence of engine masking noise. A comprehensive investigation is conducted focusing on the optimization of the first-stage transfer gear blanks to improve NVH performance and reduce mass for EV applications. A multibody dynamic model of the eDU is constructed, incorporating asymmetric gear blank geometry, shaft elasticity, bearing stiffness, and housing flexibility, to characterize realistic operating conditions and simulate gear contact mechanics with high fidelity and computational efficiency. NVH excitation sources, including static transmission error and dynamic meshing force, are systematically evaluated for solid and slotted gear configurations. Based on a DOE optimization study, an 8-slot gear blank design is selected to balance mass reduction, stress, NVH, and manufacturing requirements. Micro-geometry optimization is conducted for the slotted

He, Song, Du, Isaac, Li, Bo, Bahk, Cheonjae, Grguras, Zachary, Baladhandapani, Dhanasekar, Patruni, Pavan Kumar

Design and Performance Evaluation of a Dust Contamination Simulation Test Apparatus for Automotive Cameras

2026-01-0059

4/7/2026

This study presents the development and validation of a muddy water spray apparatus designed to simulate dust contamination on vehicle sensors for sensor cleaning system testing. It is important to have a constant and quantifiable test environment for the vehicle development process. For verifying the apparatus, muddy water, prepared by mixing standardized dust powder, salt, and water to maintain constant contamination test conditions, was sprayed onto glass specimens to evaluate equipment consistency. Deposited dust weight and thickness were measured across multiple spray cycles, with statistical analyses confirming consistent and reliable deposition. Paired t-tests indicated no significant difference between sample positions, demonstrating uniform spray distribution. The apparatus was further applied to individual infrared (IR) cameras to observe performance degradation under dry and wet contamination conditions showing statistically consistent increases in contamination levels

Jinhyeok, Gong

In-situ Decoupling and Stiffness Optimization of Resiliently Coupled Assemblies Using FRF-Based Substructuring

2026-01-0227

4/7/2026

Resilient mounts are critical in controlling vibration transfer from sources such as engines, motors, and suspension to the vehicle structure. Conventional optimization methods rely on finite element analysis (FEA), which, while accurate, is computationally intensive and limits iterative NVH development. This paper introduces a Frequency Response Function Substructuring (FBS)-based approach that decomposes the system into substructures characterized by FRFs, significantly reducing computational cost without compromising accuracy. Key contributions include: (1) recovering subsystem FRFs from coupled system data in-situ for mount optimization, (2) extending FBS to handle enforced motion, and (3) proposing an alternative strategy for cases with unknown or unmeasurable loads. The methodology is demonstrated on a mid-size pickup truck model to optimize seat track response under a Four post shake load by refining body mounts. These advances broaden the applicability of FBS for efficient NVH

Haider, Syed, Abbas, Ahmad, Jahangir, Yawar, Maddali, Ramakanth

Predictive Maintenance of EV Drive Unit Oil Pumps through Machine Learning on Fleet Telemetry Data

2026-01-0161

4/7/2026

The reliability of Drive Unit (DU) oil pumps is critical to the performance and safety of electric vehicles, as these pumps provide essential lubrication and thermal management. In modern EV architectures, real-time health monitoring of these pumps typically relies on indirect signals than dedicated sensing hardware, a design choice optimized for cost, weight, and system complexity. This makes early fault detection a non-trivial challenge. To address this limitation, we present a novel, data-driven anomaly detection framework that leverages large-scale customer fleet telemetry and advanced machine learning to identify incipient pump degradation that traditional diagnostic methods often fail to capture. Specifically, we develop an XGBoost regression model trained on time-series features—including commanded pump speed, oil temperature, and historical pump current—to predict expected current behavior under nominal conditions. Deviations are quantified using the Mean Absolute Percentage

Li, Jingman, Yao, Mengqi, Rahimi, Sahil, Lin, Joanne

Enhanced CAE Methodology to Predict Bolt Shear Failure Using Multi-Layer Approach

2026-01-0489

4/7/2026

Automotive seat system is one of the most complex systems in vehicle for its technical and functional requirements. Seat is designed to meet all regulatory requirements subjecting it to multiple tests with loading patterns which caters to the occupant safety. Varied loading and load path for different test requirements cause seat bolts to experience tensile, compressive, bending moments and shear loading. Shearing along bolt length is one of the common failure modes observed during design validation by physical tests. In the world of CAE, there is an industry approach to find the bolt failures at nut and head for all kind of loads. But shear failures along varied bolt lengths are not accurately predictable as multiple sheet metal parts will transfer loads unevenly onto bolt length and it becomes challenge to find which component is leading to shear failure. Hence by adding multiple rupture layers across the bolt length shear and its location could be predicted. Further, to resolve the

RJ, Jethendra, Chiu, Li-Ban

New Era of Automotive Cybersecurity

2026-01-0086

4/7/2026

The automotive industry is evolving from a reactive, independently self-determined approach to cybersecurity, complicated by a complex supply chain. Over time, this has resulted in a fragmented industry comprised of any number of proprietary solutions verses a standardized, regulated paradigm to facilitate a platform-oriented approach. This document, an update on collaborative work from the SAE Vehicle Electrical Hardware Security Task Force (TEVEES18B) and GlobalPlatform Automotive Task Force, outlines this transition strategy. An extensible number of additional examples of use cases of Global Platform Technologies are explored in this document.

Mazzara, Bill, Rawlings, Craig

Analyzing Fastened Joints in Hydraulic Dampers Using Simulation and Experimental Methods

2026-01-0585

4/7/2026

The main purpose of this study is to develop and validate an accurate calculation model for a hydraulic damper piston valve joint, enabling reliable torque specification and clamp behavior without full prototype iteration. Joint stiffness is a primary interest point. The joint features a bolted interface with a laminated shim stack of many thin disks with varying outer diameters. Analysis of such joints are uncommon in literature, making it challenging to quantify the effects of load distribution, truncation, and surface contact effects between members. The proposed models discussed in this paper are based on frustum load distribution combined with annular-plate bending and elastic-foundation effects to capture the effects of washer cupping. Concrete outputs of the calculator include member load distribution, bolt and member stiffnesses, torque-to-preload relationships, and an external-load simulation that predicts when individual members lose clamp load. Detailed internal hydraulic

Dresen, Gabriel, Vollmar, Race, Roy Chowdhury, Sourav

A Decision-Making Framework for Field Manufacturability of Vehicle Parts in Expeditionary Environments

2026-01-0143

4/7/2026

Expeditionary environments (such as remote exploration missions, forward military operations, and disaster response zones) demand adaptive manufacturing solutions to support vehicle sustainment in the absence of traditional supply chains. This work introduces a conceptual mathematical framework for modeling the constraints and tradeoffs inherent to expeditionary manufacturing, with a focus on vehicle repair and spare parts fabrication using low-energy and simple automated systems including desktop-scale 3D printers and CNC machines. The model integrates key variables such as energy availability, material transport cost, fabrication time, and environmental limitations to support rapid decision-making on part manufacturability and in-field feasibility. A case study involving the on-demand production of some common wear and failure parts on a vehicle, including suspension components and the water pump, is used to demonstrate how this framework can guide the selection of suitable

Mollan, Calahan, Pandey, Vijitashwa, Patterson, Albert E.

Development and Preliminary Combustion Experiments of a Prototype Engine with Sleeve Valves Based on the Focusing Compression Principle

2026-01-0295

4/7/2026

Our laboratory has proposed the focusing compression principle which employs pulsed super-multi jets of gas colliding around the chamber center. This principle aims to achieve high thermal efficiency by reducing both exhaust and cooling losses. Exhaust loss is minimized due to relatively-silent high compression. Cooling loss is reduced due to thermal insulation caused by fuel-air mixture being confined to the chamber center and the compressible flow effect. In previous studies, we conducted fundamental gasoline combustion experiments on a proof-of-concept opposed-piston engine which incorporated this principle. This engine featured eight intake nozzles in an octagonal configuration and utilized non-sinusoidal and strongly asymmetric piston movements. The results indicated the possibility of high thermal efficiency based on less knocking under high compression, and the potential for stable combustion under lean-burn conditions. As a next step towards practical application with

Nishizawa, Tomohiko, Naitoh, Ken, Baba, Shotaro, Ukegawa, Hiraku, Yamada, Sota, Ozono, Yuka, Abiko, Mirei, Suzuki, Yosuke, Hara, Namito, Ito, Yoshikuni, Matsubara, Kosaku, Uenoyama, Kazuyuki

Prediction of Pressure Pulsation in Brake Line Considering Wave Propagation Characteristics of Fluid Contained in Flexible Hose for Automotive Hydraulic Brake System

2026-01-0225

4/7/2026

Brake pulsation noise caused by fluid-borne vibration, which is generated by pressure pulsations from the pump in the Electronic Stability Control (ESC) modulator, occurs when the control brake function is activated under various driving conditions, such as Adaptive Cruise Control (ACC) and regenerative-friction brake coordination. This noise is particularly noticeable in Battery Electric Vehicles (BEVs), where the background noise from the power source is lower than that of internal combustion engine vehicles. The simulation of pressure pulsations in the brake system requires the excitation force of the pump built into the ESC modulator, the characteristics of valves, and the characteristics of the flexible hose; however, it is extremely difficult to determine these parameters with high accuracy from the design specifications. For this reason, in this study, the pump and valves were experimentally identified, while the flexible hose was represented by a three-element Voigt model to

Koike, Yohei, Komada, Masashi, Yano, Masahiro, Yoshioka, Nobuhiko

Defect Depth Characterization via Thermally and Pneumatically Induced Shearography for Component Inspection in the Automotive Sector

2026-01-0205

4/7/2026

The following approach introduces a novel method for defect depth characterization using digital Shearography, which is a non-contact, full-field, and material-independent optical interferometric method that enables fast and nondestructive testing (NDT) of components, especially in industrial environments such as the automotive sector. While traditional techniques like computed-tomography, ultrasonic-testing, or thermography can offer depth approximations but they often involve high costs, longer testing times, or limited accessibility. In contrast, the method introduced utilizes various excitation methods in combination with shearographic evaluation to derive procedures for depth estimation of subsurface defects. Recent developments in Shearography have enhanced the method’s robustness and industrial applicability. By detecting the surface deformation behavior in the nanometer range under defined loading, depth-related characteristics of hidden defects can be extracted. Loading can be

Bastgen, Valentin, Plaßmann, Jessica, Petry, Christopher, von Freymann, Georg, Schuth, Michael

A Novel Spot Joint Finite Element for Rapid Stress Analysis of Fasteners in Automotive Structures

2026-01-0182

4/7/2026

Due to the spot weld and mechanical fastener share the similar characteristics to join sheets together with differences in deformation behavior around joint region, a novel spot joint element (user-defined element) consists of regular Mindlin shell elements and equations for different kinematic constraints is proposed to simplify the spot joint representation in lightweight automotive structures. The novel spot joint element can not only provide accurate deformation behavior around joint region but also output mesh-insensitive structural stresses at virtual nodes with the use of traction-based structural stress method for fatigue failure analysis. In this investigation, the structural stress distributions around joint circumference in the lap-shear specimens with spot weld or fastener are first calculated to validate the accuracy of the novel spot joint element. Then, the structural stresses along different cross-sections emanating from joint are also calculated for the specimens with

Wu, Shengjia, Zhang, Lunyu, Dong, Pingsha

The Stellantis North America Aero-Acoustic Wind Tunnel Upgrade

2026-01-0609

4/7/2026

The Stellantis North America Aero-Acoustic Wind Tunnel (AAWT) has been upgraded with a cutting-edge 5-belt Moving Ground Plane (MGP) system, featuring an 8.5-meter center belt and four Wheel Spinning Unit (WSU) belts with advanced coatings for durability and visibility. The expanded 9.4-meter turntable enables ±90° yaw and supports vehicles with wheelbases from 1800 mm to 4500 mm and weights up to 5000 kg, accommodating the full Stellantis North America product range. The original 2-stage boundary layer control system was retained, with new tertiary slots added for improved flow quality. A high-stiffness, six-component Horiba balance with integrated calibration weights and tractive force measurement ensures accurate and precise measurements. Facility enhancements include a 550 m2 building addition for equipment and vehicle prep, a dedicated compressor container for clean air supply, and a vehicle underbody wash booth for efficient cleaning. Commissioning confirmed that flow quality

Lounsberry, Todd, Ladouceur, Brent, Fadler, Gregory