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The efforts of the ISO “Test Variability Task Force” have been aimed at improving the understanding and at reducing brake dynamometer test variability during performance testing. In addition, dynamometer test results have been compared and correlated to vehicle testing. Even though there is already a vast amount of anecdotal evidence confirming the fact that different procedures generate different friction coefficients on the same brake corner, the availability of supporting data to the industry has been elusive up to this point. To overcome this issue, this paper focuses on assessing friction levels, friction coefficient sensitivity, and repeatability under ECE, GB, ISO, JASO, and SAE laboratory friction evaluation tests.

Development of reliable magnesium (Mg) to steel joining methods is one of the critical issues in broader applications of Mg in automotive body construction. Ultrasonic spot welding (USW) has been demonstrated successfully to join Mg to steel and to achieve strong joints. In this study, corrosion test of ultrasonic spot welds between 1.6 mm thick Mg AZ31B-H24 and 0.8 mm thick galvanized mild steel, without and with adhesive, was conducted. Adhesive used was a one-component, heat-cured epoxy material, and was applied between overlapped sheets before USW. Corrosion test was conducted with an automotive cyclic corrosion test, which includes cyclic exposures of dipping in the 0.5% sodium chloride (NaCl) bath, a constant humidity environment, and a drying period. Lap shear strength of the joints decreased with the cycles of corrosion exposure. Good joint strengths were retained at the end of 30-cycle test.

It is well known that the drilling industry is a diverse industry with huge power needs for drilling deep wells. This paper discusses the drilling industry in general and the future need for HT power electronics to enable such activities as tractor drive drilling of deep horizontal wells. The discussion is geared at applications for drilling within the earth at ambient temperatures of 150°C and above.

Modern approaches to durability assurance in ground vehicle design are reviewed in the context of recent developments in computer-based analytical and experimental tools for use by designers and development engineers. Examples, using an automotive wheel assembly, are presented to illustrate the application of fatigue analysis in product development. Major challenges associated with the linking of various design tools into integrated networks appropriately configured for industrial problem solving are discussed along with an assessment of the potential benefits to be gained from such integration.

A review of many years of published work has shown that hydrogen embrittlement can occur under rolling contact conditions. Breakdown of lubrication and contamination with water have been cited as the probable sources of atomic hydrogen. In this paper, a unique fracture morphology is identified and the mechanism of the fracture progression from initiation to final catastrophic failure is proposed. Development of beneficial residual compressive stress near the contacting surfaces is one approach used to avoid this type of failure. Several alternative methods capable of developing a more desirable stress distribution will be discussed.

This numerical study examines the chemical-kinetics mechanism responsible for EGR NOx reduction in standard engines. Also, it investigates the feasibility of using EGR alone in hydrogen-air and methanol-air combustion to help generate and retain the same radicals previously found to be responsible for the inducement of the autoignition (in such mixtures) in IC engines with the SONEX Combustion System (SCS) piston micro-chamber. The analysis is based on a detailed chemical kinetics mechanism (for each fuel) that includes NOx production. The mechanism for H-air-NOx combustion makes use of 19 species and 58 reactions while the methanol-air-NOx mechanism is based on the use of 49 species and 227 reactions. It was earlier postulated that the combination of thermal control and charge dilution provided by the EGR produces an alteration in the combustion mechanisms (for both the hydrogen and methanol cases) that lowers peak cycle temperatures-thus greatly reducing the production of NOx.

Gear rattle, clunk, and other such noises, commonly referred to as impulsive or unusual noise, are often classified as unique problems without common origins. This paper examines the underlying structure that promotes them and traces physical system behaviors that predispose them to such noises. Though the audible noise itself is not modeled directly, a good deal of the disposable energy that sustains it can be inferred from the impulsive dynamics that underlies the whole process. Further effort quantifies the energies involved and appraises the distinctiveness of the perceived noise. Whether one hears gear rattle or clunk depends on the initiating site within the system and the impulsivity index of the prevailing dynamics. Observable indicators suggest that periodic noise is supported by periodic dynamics and, similarly, impulsive noise, by impulsive dynamics and that the latter is non-deterministic, discontinuous and even chaotic.

There have been plastics in automobiles almost as long as there have been plastics. This paper deals with plastic molded parts from the 1930’s through 1970. These parts include steering wheels, tail light lenses, knobs, electrical connectors, fasteners, speedometer wheels, distributor caps, water pump impellers, dials, and various decorative ornaments.

This paper deals with a conceptual aircraft cargo loader “that can do everything” commonly referred to as The Super Loader. The Super Loader is intended for use at air terminals to transport loads such as palletized cargo, containers, wheeled vehicles, shelters, and airdrop platforms from the storage docks to the military and civil aircraft, and vice versa. The loader may be described as a self-propelled, air transportable (in a C-141, C-17, C-5) 60,000 lb lifting capacity, adjustable height vehicle that will load/off load all transport aircraft from a C-130 whose cargo deck is only 3 feet, 3 inches high to a B-747 whose main deck upper limit is about 18 feet high. The Super Loader must also service the lower lobes of wide-bodies and main decks of narrow-bodied aircraft like the DC-8 and B-707. In brief, this loader will be required to interface with both civil and military cargo systems, present and future.

The late and expected improvements in balancing design of hydraulics components to be sure to use real and relatively thick films to enhance the transmission gear of forces and torques with a very low level of friction forces and pratically without heating and wear. The RAFFO process allows high performances, low sensitivity to pollution and small machining cost.

The original design-performance evaluation method of tracks and tracklaying vehicles, proposed by this writer during the WW II, was further developed and enhanced with new experience gained by many researchers. The method is based on the approximation of track action by a number of appropriate wheel actions. It is mathematically simple, and practically unique encompassing detailed track and road wheel geometry, wheel spacing, loads and load distribution together with regular soil strength parameters. It conforms methodologically with evaluation of pneumatic tires and rigid wheels, previously published in a series of SAE papers. The said papers and the present one form a concise engineering outline of Terramechanics for off-road locomotion.

Development of Terrain-Vehicle Systems Analysis involving statistically variable ground, has necessitated the development of field instrumentation for mass measurement of soil parameter input. To this end, the idea originally conceived and tested at U.S. Army's Land Locomotion Laboratory in Detroit, was revived and adapted to modern requirements. The Wheeled Automated Bevameter (WAB) was presented as a better vehicle analog for measuring soil parameters than the conventional plate-shearing instrument hitherto used. It yields itself to mass production of terrain input, without which further progress in Terramechanics, based on statistical changes of the environment may be impossible.

This paper provides a review of the fatigue properties reported in the open literature for die cast magnesium-based alloys. Recently developed fatigue data, in the form of stress versus number of cycles to failure for bending fatigue (R=-1), are presented for die cast AM60B and AZ91D alloy specimens with thicknesses between 1 and 10 mm. The effects of specimen thickness and macrostructural features, such as porosity distributions and surface features (parting line and ejection pin marks), on the fatigue data are discussed.

Hydraulic fluids of the HFC category are aqueous polymer solutions with a fire resistance enhancing water content of 35 to approx. 50 %. The use of HFC fluids, above all in mobile and stationary drives in mining and in casting is subject to restrictions resulting from a number of features of a fluid. Field practice has shown that while axial-piston pumps may be successfully operated using HFC fluids, rolling bearing failures reduce their operational lifetimes. The bearing failures essentially result from material fatigue. This can be remedied by new quality steel for roller bearings. The combination of high fatigue life and corrosion resistance assures a wide application range for nitrogen-treated steel qualities.

Reported tensile and fatigue properties of die cast AZ91D and AM60B magnesium alloys indicate that those values depend on the size and shape of the test samples and their global porosities. This paper reviews the mechanical properties reported in the open literature for these die cast alloys and indicates that section thickness and global porosity are inadequate for predicting the tensile and fatigue properties of die cast AZ91D and AM60B magnesium alloys.

Die cast AZ91D and AM60 magnesium alloy components are finding increasing usage in automotive applications. Both hot and cold chamber die cast components of these alloys generally exhibit several common microstructural features, including “skin”, porosity banding, and porosity distributed about the component centerline. Methods for quantitatively characterizing these microstructural features are described and representative values for skin thicknesses, porosity band dimensions and porosity band locations from selected die castings will be presented. The expected influence of these common microstrucutral features on mechanical properties and acceptability of die cast magnesium components for given applications are discussed.

Several of the authors have recently developed procedures to efficiently evaluate experimentally the relative contributions of various wind noise paths and sources. These procedures are described and, as a case study, results are provided for the noise in the interior of a production automobile subjected to wind tunnel airflow. The present measurements and analysis indicate that for the tested vehicle significant contributions to interior noise are provided by underbody and wheel well flows, radiation from the roof and seal aspiration. A significant tone associated with vortex shedding from the radio antenna was also noted.

A unique system would solve traffic, fossil-fuel depletion, and environmental problems. Dual-mode private and commercial vehicles would be manually driven on streets and automatically controlled on maglev guideways. Busses and freight vehicles without wheels or drivers also used. Proposed guideway speeds: 100kph in cities, and 325kph between cities. System would be safer and have much higher capacity than existing highways or proposed “smart car” systems. One-third meter clearance between cars to be achieved by linear synchronous-motor propulsion. Capacity of single 100kph guideway to equal that of twelve highway lanes, and one 325kph guideway would be equivalent to forty highway lanes.