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2015-06-09
Event
2015-06-09
Event
2015-06-09
Event
2015-05-11
Event
2015-04-22
Event
This symposium provides a forum for researchers and application engineers to disseminate the knowledge and information gained in the area of advanced high-strength and press-hardening steel development and applications in automotive structures, enabling light-weight and durable vehicles with improved safety.
2015-04-22
Event
This symposium provides a forum for researchers and application engineers to disseminate the knowledge and information gained in the area of advanced high-strength and press-hardening steel development and applications in automotive structures, enabling light-weight and durable vehicles with improved safety.
2015-04-22 ...
  • April 22-24, 2015 (8:30 a.m. - 4:30 p.m.) - Detroit, Michigan
  • August 5-7, 2015 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
  • December 16-18, 2015 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
Training / Education Classroom Seminars
Attendees to the seminars held in conjunction with the SAE 2015 World Congress will receive COMPLETE access to Congress activities for only $55 per day. If interested, please contact our Customer Service department at +1.877.606.7323 (U.S. and Canada only) or +1.724.776.4970 (outside U.S. and Canada) to register for this special Congress daily rate. There is a potential for metal fatigue in any situation where a component is subjected to cyclic loads. Fatigue failures of various types are a key concern in increasing the reliability of products.
2015-04-20 ...
  • April 20-21, 2015 (8:30 a.m. - 4:30 p.m.) - Detroit, Michigan
  • October 29-30, 2015 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
Training / Education Classroom Seminars
Attendees to the seminars held in conjunction with the SAE 2015 World Congress will receive COMPLETE access to Congress activities for only $55 per day. If interested, please contact our Customer Service department at +1.877.606.7323 (U.S. and Canada only) or +1.724.776.4970 (outside U.S. and Canada) to register for this special Congress daily rate. Preventing future problems and troubleshooting existing problems in today's stamping plants requires greater stamping process knowledge. The link between inputs and outputs isn't as clear as many think, increasing the need for detailed understanding of the variables involved.
2015-04-14
Technical Paper
2015-01-0526
Timo Faath, Lay Knoerr
In the new ThyssenKrupp InCar®plus project, numerous solutions were developed for body parts and systems that contribute to increased efficiency through the use of new materials and manufacturing technologies. They are superior to current production solutions in terms of weight, cost, performance and sustainability, while also meeting the demand for cost-effective weight reduction. One example is the front bumper: This part offers major weight reduction potential in the front end of the car. Both steel and aluminum versions are currently in serial production. In the ThyssenKrupp InCar®plus project, a highly efficient steel solution was developed that matches the weight level of current aluminum solutions at much lower cost. The hot-formed lightweight steel crash beam is around 20% lighter than conventional steel solutions. The latest safety requirements such as the new R-CAR barrier test and the IIHS Small Overlap Test were taken into account during development.
2015-04-14
Technical Paper
2015-01-0459
Vesna Savic, Louis Hector, Hesham Ezzat, Anil Sachdev, James Quinn, Ronald Krupitzer, Xin Sun
This paper presents an overview of a four-year project on integrated computational materials engineering (ICME) for third generation advanced high-strength steels (3GAHSS) development. Following a brief look at ICME as an emerging discipline within the Materials Genome Initiative, technical tasks in the ICME project will be discussed. Specific focus of the individual tasks is on multi-scale, microstructure-based material model development using state-of-the-art computational and experimental techniques, forming, assembly, design optimization, integration and technical cost modeling. The integrated approach is illustrated using a 980 grade transformation induced plasticity (TRIP) steel with a two-step quenching and partitioning (Q&P) heat treatment as an example.
2015-04-14
Technical Paper
2015-01-1102
Katsuhiko Ohishi, Toshihiro Uehara, Ichirou Kishigami
In recent years, fuel economy improvement of automobiles is required to reduce emissions of carbon dioxide (CO2) which is a greenhouse gas and is well known as one of the factors of global warming. Therefore, continuously variable transmissions (CVT) have been used increasingly, because they are light, compact and contribute to better fuel consumption. Metal belt CVTs are the most popular system in use today. 18mass%Ni maraging steel is used for CVT belts because it has good weldability, good formability and high fatigue strength. Maraging steels strengthened by Ti have high fatigue strength, but TiN particles, which are the main non-metalic inclusions inside steels, might cause fatigue cracks in high cycle regions over 107 cycles. At present there is a special melting process to minimize TiN particle size, but we need further technological innovations to improve fatigue strength.
2015-04-14
Technical Paper
2015-01-0405
Carol Schutte
One of the goals for the Vehicles Technology Office in DOE is to reduce our dependency on oil and reduce emissions of greenhouse gases. Transportation is responsible usage of 2/3 of U.S. petroleum. With over 240M vehicles on the road, these vehicles are responsible for usage of 80% of transportation petroleum. Reducing our reliance on petroleum contributes to greater economic and energy security as well as providing responsible stewardship of the environment. DOE’s strategy for reducing the use of petroleum focuses on the displacement of petroleum with alternate fuels and electrification, and significantly improving the efficiency of vehicles. One aspect of increased efficiency is to cost effectively reduce the weight of the vehicle, while maintaining performance and safety requirements.
2015-04-14
Technical Paper
2015-01-0738
Joseph R. Kish, Zach Cano, Alexandra Kobylecky, Joseph McDermid, Timothy Skszek, John Kukalis
The purpose of this study was to conduct a comparative corrosion assessment of alloys and coating schemes of interest for the fabrication of multi-material lightweight vehicle architectures. Alloys considered for this application included galvanized steel, aluminum alloy 6111 and magnesium alloy ZEK100. The coating scheme considered for corrosion protection included a typical paint scheme (clear coat over top base coat enamel) applied to the alloy surface pre-treated using a commercially available conversion coating and electrocoated prior to painting. The magnesium ZEK100 alloy was also tested with an alternative plasma electrodeposition pre-treatment process applied to the surface as part of the coating scheme. The corrosion assessment of the scribed coated alloys was conducted after 1000 h exposure in the ASTM B117 salt fog environment.
2015-04-14
Technical Paper
2015-01-0245
Markus Gaertner
The benefits of aluminum as a conductor material are the reduction of mass, to minimize CO2 consumption in combination with low material cost. The intermediate aluminum cable cross section 2.5mm² - 6.0mm² cover a good potential for car implementation to hit this goal. The presentation describes the technical solutions for an aluminum wiring harness equipped with aluminum cable in the cross section of 2.5mm² - 6.0mm². Next to the connection technologies ultra-sonic welding and crimp technology, the presentation informs about the new SMC - technology for corrosion protection. SMC is the abbreviation for selective metal coating. This technology based on a material optimization for the crimp design of the terminal. It offers for the designer a modular approach of corrosion protection specific to its used compartment within the vehicle.
2015-04-14
Technical Paper
2015-01-0705
Koichi Taniguchi, Hiroshi Matsuda, Rinsei Ikeda, Kenji Oi
High joint strength of resistance spot welds is necessary for high rigidity and reliability of car body using ultra high strength steel (UHSS) sheets with tensile strength over 980MPa. We developed “pulsed current pattern” consisting the combination of short cool time and short-time high-current post-heating. This new process can achieve high cross tension strength (CTS) with sufficient tensile shear strength (TSS) in shorter welding time than conventional temper pattern. This paper presents the heating pattern and the effect on the joint strength by pulsed current pattern. Finite element analysis (FEA) for post-heating patterns was conducted using SORPAS. Temperature dependent material properties of 1180MPa grade steel were taken into account. FEA shows that the short-time high-current post-heating leads to rapid heating in nugget and heat affected zone (HAZ) compared to conventional temper pattern consisting long-time low-current post-heating.
2015-04-14
Technical Paper
2015-01-0408
Jeff Conklin, Randy Beals, Zach Brown
Vehma / Cosma Engineering International, the U.S. Department of Energy and Ford Motor Company initiated the Multi Materials Lightweight Vehicle (MMLV) Project in 2012. The goal of producing a multi-material vehicle, approximately 25% mass reduction relative to the baseline has been achieved. This paper reviews the mass reduction and structural performance of aluminum high pressure vacuum die cast (hpvdc) applications for a lightweight, multi-material body in white (BIW) relative to a C/D segment production vehicle. Selected stiffness, durability and crash requirements are assessed. The structure incorporates aluminum castings, extrusions and sheet as well as steel sheet, assembled using structural adhesive bonding and a variety of joining technologies. No other body structure in high volume production incorporates this combination of materials and joining processes.
2015-04-14
Technical Paper
2015-01-0410
Kevin Smith, Ying Zhang
MMLV Corrosion Mitigation Kevin D Smith1, Ying Zhang1 1 Magna International ABSTRACT Magna International, the U.S Department of Energy and Ford Motor Company initiated the Multi Materials Light Vehicle (MMLV) program in 2012, in an effort to reduce vehicle mass. A full-vehicle mass reduction of 23.5% was successfully achieved, and with it comes a host of new challenges in the form of overall vehicle corrosion protection and prevention in the use of multi lightweight materials. This paper will present the test results relative to two (2) corrosion mitigation strategies associated with a common multimaterial body-in-white (BIW) structure. The “conventional” corrosion mitigation strategy included a pretreated and E-coated fully assembled BIW structure. The “alternative” corrosion mitigation strategy included integration/assembly of seven (7) corrosion protected BIW module subassemblies, prior to integration of the modules in a BIW Framing Station.
2015-04-14
Technical Paper
2015-01-1239
Neal J. Corey, Mark Madin, Rick L. Williams
While weight reduction in automotive design and manufacturing have been on-going for several years, in the area of powertrain technology, light-weighting has been a difficult challenge to overcome due to functional requirements, as well as material and manufacturing constraints. Ford Motor Company, as part of the Multi Material Lightweight Vehicle (MMLV) project with Vehma International and the US Department of Energy, worked with its material supplier, BASF, to design and develop a carbon fiber Front Cover and Oil Pan, based off the current Fox I3 Gasoline Turbocharged Direct Injection (GTDI) Engine. The effort produced a reduced weight Front Cover and Oil Pan, that were both structurally strong enough to support the engine attachment to the frame rail and as well as meeting all the powertrain bending stress targets that are seen in the current engine.
2015-04-14
Technical Paper
2015-01-1237
Xiaoming Chen, Jeff L. Conklin, Mike Carpenter, Jeff Wallace, Cynthia Flanigan, David Wagner, Vijitha Kiridena, Stephane Betrancourt, Jason Logsdon
As part of the Ford and Vehma collaborative efforts on the DOE sponsored project on Multi Materials Lightweight Vehicle, several automotive chassis components were identified for development and evaluation on a lightweight passenger vehicle. The lightweight prototype chassis parts included composite and hollow steel coil springs, carbon fiber wheels, tires with a tall and narrow design, hollow steel stabilizer bars, and an aluminum front cradle. The lightweight chassis parts development included mixed and multi materials to investigate potential weight savings. The glass fiber reinforced composite front spring and hollow steel rear springs achieved 59% and 37% weight savings respectively. Both springs passed required component tests and survived proving ground durability test with no issues detected. For the lightweight tall narrow tires, evaluations were conducted on three distinct sets of tires with varying material constructions and final weight in the range of 17 pounds per tire.
2015-04-14
Technical Paper
2015-01-0520
Takaaki Kitahara, Takuo Imai, Osamu Ishigo, Miodrag Perovic
In recent years, there has been a requirement for automotive bearings materials to be free of the toxic material lead, in accordance with ELV regulations and from the perspective of environmental problems. Currently, bismuth is often used as a replacement for lead in copper alloy based main bearings and connecting rod bearings for automotive engines. Previous bismuth-containing copper alloy bearing materials have shown satisfactory seizure resistance, but conformability has not been as good as for lead-containing bearing materials. As a result, they have been successfully applied to automotive diesel engines, but not for truck engines where improved conformability is required to better accommodate irregularities such as foreign particles. To improve the conformability, a softer bearing material is desirable. Furthermore, in recent years bearing materials containing hard particles have been widely used with the improvement of seizure resistance and wear resistance.
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