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Viewing 1 to 30 of 3618
2015-06-15
Technical Paper
2015-01-2136
Francisco José Redondo
Due to weight constraints, the engine air intake for the Airbus A400M Transport Airplane will be all made in aluminum, and by specification, the intake is protected against ice accretion by a hot air system. In order to assure a fatigue life of the element for the life of the airplane, the temperature of the air supplied must be controlled to a maximum value consistent with aluminum characteristics. A system has been designed wherein hot air is bled and cooled by coolant air from inside the nacelle with a jet pump.While maximum temperature was a constraint for the design of the system, several other constraints appeared during the detailed design of the system; - the tight space allocation inside the nacelle limited the length of the jet pump, - the low temperature provided by the engine bleed in flight idle limited the secondary flow used to cool the engine bleed, and - the complex air distribution needed to supply air to the intake areas. Two variants of the system were developed.
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
2015-01-1340
Yoichi Toyooka, Kiyoshi Hasegawa
Warping the exteriors of outer panels happens during the application of heat for hardening structural adhesives. Using aluminum and resin promote warping. Simulation of warping at the design stage and evaluating warping during mass-production require us to quantify the degree of warping to evaluate absolute values. These analytic values correspond to values from warping in panels, and display a correlation with visual examinations. Degree of displacement was an evaluative indicator for the quantification of warping. However, warping will not always be recognized due to gradual change in areas of the panel and cases where it will be recognized due to sudden change, despite that the absolute value of the degree of displacement might be the same. This research considered a warping simulation and evaluation using curvature as the evaluative indicator. Curvature is the gradient of change of the curved surface.
2015-04-14
Technical Paper
2015-01-1370
Mehran Ebrahimi, Kamran Behdinan
Energy consumption is one of the most significant challenges in the world today, and has been the source of many struggles in international level. The future of human’s generations is in serious danger because of energy related issues such as resources shortage and global warming. Hence, responsible governments have codified some policies to reduce fuel consumption in energy-dependent industries and their products. Automobile industries as the manufacturers of fuel consumer products are not exempt from these rules, and are always looking for more lightweight industrial designs. In order to achieve more lightweight solutions, changing the material of an available part to a lower density one is the first option in many applications, and aluminum as an accessible material with acceptable mechanical properties can be a suitable replacement for steel in the majority of industrial demands.
2015-04-14
Technical Paper
2015-01-0237
Nick Smith
Abstract The architecture of vehicle electrical systems is changing rapidly. Electric and hybrid vehicles are driving mixed voltage systems, and cost pressures are making conductor materials like aluminum an increasingly viable competitor to copper. The challenge of assessing the impact of these technologies on vehicle safety and of understanding cost/weight trade-offs is a critical design activity. This session will discuss and demonstrate tradeoff studies at the vehicle level, show how to automatically generate an electrical Failure Mode Effects and Analysis (FMEA) report, and optimize wire sizes for both copper and aluminum at the platform level.
2015-04-14
Technical Paper
2015-01-0244
Adrien Laurino
Abstract For tubular terminals and high power junctions, the magnetic pulse crimping (MPC) could be a technical solution to produce aluminum - copper assembly. LEONI has launched a study to evaluate this technology. Besides, the lifetime of vehicle components is an issue that manufacturers should consider during all the development phases from the conception to the validation in service. Consequently, the quality of the interface aluminum-copper obtained by MPC is evaluated in terms of microstructure, of electrical and mechanical properties and to describe the corrosion behavior.
2015-04-14
Technical Paper
2015-01-0245
Markus Gaertner
Abstract Historically aluminum was recognized as a valuable material to achieve weight reduction targets in engines, vehicle chassis and suspension. Aluminum needs to be also considered in new areas like vehicle electrification to support the overall weight reduction targets. The use of aluminum helps to improve fuel economy and brings down CO2 emissions by reducing weight. This benefit is an attractive option for the wiring harness to replace heavier copper conductors. In addition to large cross section wires for power cable, where aluminum conductors are already in use, the intermediate aluminum cable cross section of 2.5mm2 to 6.0 mm2 provides a good potential for car implementation to hit weight saving targets. The major implementation roadblocks for aluminum technology are the surface oxides Al2O3 which are an insulator and the potential galvanic corrosion of aluminum in combination with the always present copper terminal.
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
2015-01-0409
Larry Plourde, Michael Azzouz, Jeff Wallace, Mari Chellman
Title: MMLV Door Design and Component-level Testing Authors: Magna International: Larry Plourde & Mari Chellman Ford Motor Company: Mike Azzouz This paper reviews the mass reduction and structural performance of aluminum, magnesium, and steel components associated with a light weight multi-material door design relative to a C/D segment production vehicle. Stiffness, durability, and crash requirements are assessed. The structure incorporated aluminum sheet, aluminum extrusion, magnesium high pressure vacuum die casting and steel sheet. The multi-material components were assembled using structural adhesive bonding (hem and structure), self-pierce rivets (SPR's), single sided rivets, and bolts. The aluminum extrusion and the magnesium casting in the MMLV door were specifically designed to maximize stiffness, reduce part count and maximize mass reduction.
2015-04-14
Journal Article
2015-01-1754
Wei-Jen Lai, Jwo Pan
Abstract In this paper, the analytical stress intensity factor and J integral solutions for welds in lap-shear specimens of two dissimilar sheets based on the beam bending theory are first reviewed. The solutions are then presented in the normalized forms. Next, two-dimensional finite element analyses were selectively conducted to validate the analytical solutions based on the beam bending theory. The interface crack parameters, the stress intensity factor solutions, and the J integral solutions for welds in lap-shear specimens of different combinations of steel, aluminum, and magnesium, and the combination of aluminum and copper sheets of different thickness ratios are then presented for convenient fracture and fatigue analyses. The transition thickness ratios for critical crack locations for different combinations of dissimilar materials are then determined from the analytical solutions.
2015-04-14
Technical Paper
2015-01-0594
Xin Xie, Changqing Du, Xiaona Li, Yi-Hsin Chen, Guobiao Yang, Yongjun Zhou, Dajun Zhou, Yaqian Zheng, Bernard Sia, Christina Phillips, Lianxiang Yang
Abstract This paper introduces an industrial application of digital image correlation technique on the measurement of aluminum edge stretching limit. In this study, notch-shape aluminum coupons with three different pre-strain conditions are tested. The edge stretching is proceeded by standard MTS machine. A dual-camera 3D Digital Image Correlation (DIC) system is used for the full field measurement of strain distribution in the thickness direction. Selected air brush is utilized to form a random distributed speckle pattern on the edge of sheet metal. A pair of special optical lens systems are used to observe the small measurement edge area. From the test results, it demonstrate that refer to the notched coupon thickness, pre-tension does not affect the fracture limit; refer to the virgin sheet thickness, the average edge stretch thinning limits show a consistent increasing trend as the pre-stretch strain increased.
2015-04-14
Technical Paper
2015-01-0598
Xiaona Li, Changqing Du, Yongjun Zhou, Xin Xie, Xu Chen, Yaqian Zheng, Thomas Ankofski, Rodrigue Narainen, Cedric Xia, Thomas Stoughton, Lianxiang Yang
Abstract Accurate determination of the forming limit strain of aluminum sheet metal is an important topic which has not been fully solved by industry. Also, the effects of draw beads (enhanced forming limit behaviors), normally reported on steel sheet metals, on aluminum sheet metal is not fully understood. This paper introduces an experimental study on draw bead effects on aluminum sheet metals by measuring the forming limit strain zero (FLD0) of the sheet metal. Two kinds of aluminum, AL 6016-T4 and AL 5754-0, are used. Virgin material, 40% draw bead material and 60% draw bead material conditions are tested for each kind of aluminum. Marciniak punch tests were performed to create a plane strain condition. A dual camera Digital Image Correlation (DIC) system was used to record and measure the deformation distribution history during the punch test. The on-set necking timing is determined directly from surface shape change. The FLD0 of each test situation is reported in this article.
2015-03-30
Technical Paper
2015-01-0088
Suresh Kumar Kandreegula, Naveen Sukumar, Sunil Endugu, Umashanker Gupta
Abstract To compete with the current market trends there is always a need to arrive at a cost effective and light weight designs. For Commercial Vehicles, an attempt is made to replace existing Gear Shift Fork from FC Iron (Ferro Cast Iron) to ADC (Aluminum Die Casting) without compromising its strength & stiffness, considering/bearing all the worst road load cases and severe environmental conditions. ADC has good mechanical and thermal properties compared to FC Iron. Feasible design has been Optimized within the given design space with an extra supporting pad for load distribution. Optimization, Stiffness, Contact pattern has been done using OptiStruct, Nastran & Ansys for CAE evaluation. A 6-speed manual transmission is used as an example to illustrate the simulation and validation of the optimized design. Advanced linear topology optimization methods have been addressed as the most promising techniques for light weighting and performance design of Powertrain structures.
2015-03-25
WIP Standard
AMS4004E
This specification covers an aluminum alloy in the form of foil. This foil has been used typically for corrugated or expanded honeycomb core material for use in sandwich construction, but usage is not limited to such applications.
2015-03-25
WIP Standard
AMS4190K
This specification covers an aluminum alloy in the form of welding wire. This wire has been used typically as filler metal for gas-metal-arc or gas-tungsten-arc welding of aluminum alloys of similar composition, but usage is not limited to such applications.
2015-03-25
WIP Standard
AMS4191K
This specification covers an aluminum alloy in the form of welding wire. This wire has been used typically as filler metal for gas-metal-arc or gas-tungsten-arc welding of aluminum alloys of similar composition where the joint is capable of being heat treated to a strength level comparable to that of the parent metal, but usage is not limited to such applications.
2015-03-25
WIP Standard
AMS4189J
This specification covers an aluminum alloy in the form of welding wire. This wire has been used typically as filler metal for gas-metal-arc or gas-tungsten-arc welding of heavy sections of aluminum alloys of similar composition to produce joints having inherently low dilution ratio of base-metal to weld-metal, and where the weldment may require solution and/or precipitation heat treatment, but usage is not limited to such applications.
2015-03-25
WIP Standard
AMS4219G
This specification covers an aluminum alloy in the form of castings.
2015-03-25
WIP Standard
AMS4241E
This specification covers an aluminum alloy in the form of castings. These castings have been used typically for structural aircraft components (See 8.3) requiring DAS quality control, but usage is not limited to such applications.
2015-03-25
WIP Standard
AMS4261G
This specification covers an aluminum alloy in the form of investment castings. These castings have been used typically for components requiring low weight, moderate strength and soundness, but usage is not limited to such applications.
2015-03-25
WIP Standard
AMS4871H
This specification covers an aluminum bronze alloy in the form of centrifugal and chill castings.
2015-03-25
WIP Standard
AMS4068F
This specification covers an aluminum alloy in the form of drawn seamless tubing 0.029 to 0.500 inch (0.74 to 12.70 mm) in nominal wall thickness. This tubing has been used primarily for structures requiring good fusion weldability and a combination of good strength and resistance to stress corrosion cracking after precipitation heat treatment, but usage is not limited to such applications.
2015-03-25
WIP Standard
AMS4077H
This specification covers an aluminum alloy in the form of sheet and plate. This product has been used typically for structural components, including machine tapered parts, but usage is not limited to such applications.
2015-03-25
WIP Standard
AMS4071N
This specification covers an aluminum alloy in the form of drawn, round seamless tubing. This tubing has been used typically for parts, such as hydraulic systems and fuel and oil lines, but usage is not limited to such applications.
2015-03-25
WIP Standard
AMS4182H
This specification covers an aluminum alloy in the form of wire. This wire has been used typically for the manufacture of screen for reinforcement of, and to provide electrical conductivity through, rubber gaskets, but usage is not limited to such applications.
2015-03-25
WIP Standard
AMS4079H
This specification covers an aluminum alloy in the form of drawn, round, seamless tubing. This tubing has been used typically for ducts requiring small radius bends and moderate strength after solution and precipitation heat treatment, but usage is not limited to such applications.
2015-03-25
Standard
AMS3604
This specification establishes requirements for a heat resistant aluminized organic coating with sufficient corrosion and erosion resistance for the finished substrate.
2015-03-19
Standard
J2635_201503
This test procedure defines a laboratory procedure for generating and evaluating filiform corrosion on painted aluminum wheels and painted aluminum wheel trim. While this test was developed specifically for the testing of painted aluminum wheels and wheel trim it may be applicable to other components. The application owner will need to assess if this test generates filiform similar to that found in the relevant usage to ensure it will provide accurate data for the application.
2015-03-18
WIP Standard
AMS4474A
This product has been used typically for aerospace srructural parts requiring strength similar to that of 7475-T7351 but having 4% lower nominal density, but usage is not limited to such applications.
2015-03-04
WIP Standard
AMS4824E
This specification covers bearings of a leaded bronze cast on one or both faces of a steel backing with a layer of babbitt metal cast on the leaded bronze.
Viewing 1 to 30 of 3618

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