SAE/USCAR Cooperative Research Project
New SAE/USCAR Document Published
SAE’s Cooperative Research Program, under contract with USCAR Strategic Standardization Board (SSB), has been providing USCAR with document facilitation services. SAE’s knowledge and experience in standards and cooperative research make SAE an ideal organization for this project.
SAE/USCAR-1 Revision 1
Salt Spray Testing and Evaluation of Fastener Finishes
This procedure is used to test and evaluate the resistance of fastener surface finishes to laboratory salt spray testing.
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SAE/USCAR-2 Revision 5
Performance Specification for Automotive Electrical Connector Systems
Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in low voltage (0 - 20 VDC) road vehicle applications. These procedures are only applicable to terminals used for In-Line, Header, and Device Connector systems with and without Shorting Bars. They are not applicable to Edge Board connector systems, twist lock connector systems, > 20 VAC or DC, or to eyelet type terminals.
Note: Some tests detailed in this document such as connector environmental or terminal electrical may be applicable to twist lock systems. For twist lock connector system ergonomic requirements refer to USCAR 25.
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SAE/USCAR-3 Revision 3
Specification for Testing Automotive Miniature Bulbs
The procedures contained in this specification cover the laboratory testing of miniature incandescent bulbs for use in automotive illumination and signaling applications. The following tests shall be run whenever the following occurs:
- New bulb design
- Design or process change made to an existing bulb, which could affect the outcome of the test.
- The completion of one calendar year as noted in the following Test Schedule Table. Process control data is acceptable. (see full document for table)
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SAE/USCAR-4
Standard for Cigar Lighters & Power Outlets
This standard covers the operational, reliability, durability, acceptance and testing requirements for a front-loaded, external contact cigar lighter for installation in production vehicles. SAE/USCAR-4 also covers power outlets based on the form and dimensions of the lighter receptacle.
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SAE/USCAR-5 Revision 3
Avoidance of Hydrogen Embrittlement of Steel
This standard outlines the conditions that enhance the risk of hydrogen embrittlement of steel and define the relief procedures required to minimize the risk of hydrogen embrittlement. It is intended to control the process.
1.1 Hydrogen embrittlement of steel, which can cause brittle fractures under stress, occurs as a result of the absorption of hydrogen during cleaning, phosphate coating and plating processes. The susceptibility to hydrogen embrittlement increases with increasing stress (internal or externally applied stress) and increasing material strength.
1.2 Hardness readings in this specification are in Vickers scale. SAE J417 should be referred to for conversion to other scales.
NOTE 1: All references to temperatures relate to part core temperature and not the indicated oven air temperature. Statistical data of verifications in temperature at the center of the oven load and oven temperature shall be established to develop the oven profile. The temperature of parts in a batch type of baking furnace shall be monitored with a thermocouple placed in the middle of the load. For continuous bake ovens a temperature trace through the oven must be run with a calibrated thermocouple in the lowest temperature position, at least once a year.
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SAE/USCAR-6
Standard for DC Brush Motors - HVAC Blowers
Sets the performance and durability requirements for 12-volt, D.C. brush-type electric motors used for automobile heating, ventilation and air conditioning (HVAC) blowers. It also outlines Production Validation and Continuing Conformance testing.
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SAE/USCAR-7
Deembrittlement Verification Test
This standard outlines test methods and practices to detect embrittlement of steel parts. SAE/USCAR-7 is a process control or referee verification test. The risk of embrittlement of steel is minimized by using best practices in the finishing/coating process. One such practice is described in SAE/USCAR-5, Avoidance of Hydrogen Embrittlement of Steel.
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SAE/USCAR-8 Revision 2
Grain Flow Pattern for Bolts and Screws
This specification covers the grain flow pattern requirements in headed bolts, screws, and studs. The heading practice in the manufacture of the bolt, screw, or stud sets the grain flow pattern, but it is also greatly influenced by the fastener design.
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SAE/USCAR-9
Classification System for Automotive Tooling, Machinery and Equipment Low VOC Waterborne Paint Systems
The materials defined in USCAR/SAE Recommended Practice are low VOC water based coatings for automotive tooling, and general maintenance.
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SAE/USCAR-10 Revision 2
Test for Evaluating the Torque-Tension Relationship of Both External and Internal Metric Thread Fasteners
This standard provides a test method for determining the torque-tension relationship of both external and internal metric threaded fasteners for the purpose of measuring the frictional characteristics of the threaded fasteners. The results obtained by this test are relevant to the test conditions only and should not be utilized for specific applications.
1.1 The test shall consist of a single installation of the sample fastener in a test fixture using a constant speed power tool. The test sample shall be assembled onto an appropriate mating test part (i.e., a nut will be tested by being driven onto a test screw). The test sample shall be driven against a test washer as the bearing surface.
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SAE/USCAR-11 Revision 1
Torque-Tension Testing and Evaluation of Fastener Finishes
This standard provides a test method for determining the torque-tension relationship of a fastener finish as applied to a surrogate screw for the purpose of measuring the frictional characteristic of the fastener finish. The results obtained by this test shall be used as a process control attribute of the fastener finish and shall not be utilized for specific applications.
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SAE/USCAR 12 revision 3
Wiring Component Design Guidelines
This document gives general guidelines to be used during the connector design stage. Various guidelines may not apply in all situations. Therefore, sound engineering judgment must be used in their application. Consider these guidelines as the basis for connector and wiring DFMEA's. Items in this document are grouped by DFMEA functional requirements. Groups are as follows:
- Electrical Continuity
- Electrical Isolation/Sealing
- Device Assembly
- Harness Assembly
- Vehicle Assembly
- Materials
- Serviceability
- Environmental Requirements
- High Voltage (= 60V) Application Requirements
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SAE/USCAR-13
Standard for In-Tank Electric Fuel Pumps
Covers the operational characteristics, environment, durability procedures, and test procedures for in-tank electric fuel pumps for automotive gasoline applications.
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SAE/USCAR-14 Revision 2
Specification for Testing Automotive Halogen Light Sources
The procedures contained in this specification cover the laboratory testing of replaceable halogen incandescent bulbs for use in automotive road illumination. The following tests are intended to be run under the following conditions:
- New bulb design
- Design or process change made to an existing bulb, which could affect the outcome of the test
- The completion of one calendar year, accept as noted in the following Test Schedule Table.
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SAE/USCAR-15 Revision 3
Specification for Testing Automotive Light Bulb Sockets
This specification establishes the requirements and test procedures for automotive miniature bulb retention devices, including wedge base sockets with integral connector, direct wire wedge base sockets, circuit plate assemblies, and associated interfaces.
Tests shall follow the sequence shown in the flow charts in Appendix E whenever the following occurs:
- New design
- Design, material or process change made to an existing device, which could affect the outcome of the test.
The test sequence shown in Appendix F shall be run annually.
(NOTE: Production process control data collected at a shorter interval per an approved control plan, may be substituted if approved by customer's responsible engineer and purchasing representative.)
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SAE/USCAR-17 Revision 2
Performance Specification for Automotive RF Connector Systems
1. Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors and components for coaxial cable connection systems (hereafter referred to as RF connectors) intended for road vehicle applications.
2. The intent of this specification is to qualify RF connectors that operate at frequencies greater than 200 MHz. This does not exclude lower frequency applications; the acceptance criteria may not apply, however (i.e., the AM/FM acceptance criteria is specified on Page 3 of USCAR print 999-U-001-1-A01
3. This specification does not apply to single conductor wire or twisted pair connection systems.
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SAE/USCAR-18 Revision 2
FAKRA SMB RF Connector Supplement
This document is a supplement to DIN 72594 and is intended to give recommended usages for one and two way connectors and dimensional requirements for 2-way connectors which are not currently specified by DIN. The radio frequency (RF) connector interface specified herein is suited for unsealed automobile applications up to 3 GHz and is intended for in-line, board mount, device mount, straight or angled applications. Dimensional requirements are specified in this document to ensure interchangeability. Performance requirements are specified in SAE/USCAR-2, and in SAE/USCAR-17.
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SAE/USCAR-19 Revision 1
Coaxial Cable Connector Interface - Square Outer Conductor
This radio frequency (RF) connector interface specification is suited for unsealed automobile applications up to 2 GHz. Dimensional requirements are specified in this document to ensure interchangeability.
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SAE/USCAR-20 Revision 1
Field Correlated Life Test Supplement to SAE/USCAR-2
This specification details the procedure for testing the performance of electrical connections to a test sequence (FCLT-Field Correlated Life Test) that has been correlated to automotive vehicle conditions.
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SAE/USCAR-21 Revision 2
Performance Specification for Cable-to-Terminal Electrical Crimps
This specification defines basic test methods and requirements for solder-less crimped connections.
Note: This specification was developed for use with stranded automotive copper wire. Wire types using compressed, compacted, or solid core construction or other core materials (clad, steel core, etc) need to be reviewed to determine if this specification is applicable.
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SAE/USCAR-23
Road Vehicles - 60 V and 600 V Single Core Cables - Dimensions, Test Methods and Requirements
This International Standard specifies the dimensions, test methods, and requirements for single core 60 V cables intended for use in road vehicle applications where the nominal system voltage is >= (60 V DC or 25 V AC). It also specifies additional test methods and/or requirements for 600 V cables intended for use in road vehicle applications where the nominal system voltage is > (60 V DC or 25 V AC) to >= (600 V DC or 600 V AC). It also applies to individual cores in multi-core cables. See ISO 6722 for "Temperature Class Ratings".
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SAE/USCAR-24
USCAR Inflator Technical Requirements and Validation
This specification establishes the performance, and validation requirements for the inflator assembly used in airbag modules. Pretensioners are covered only in respect to their effluents as included in Section 3.2.3, Effluents and their autoignition performance as included in Section 3.2.5, Autoignition, High Temperature Oven Performance/Autoignition of Heat Aged Inflators.
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SAE/USCAR-25 Revision 1
Electrical Connector Assembly Ergonomic Design Criteria
This document describes the design, assembly force, and packaging guidelines for conventional hand-plug, mechanical assist and twist lock electrical connectors, as well as Connector Position Assurances (CPAs). All possible designs and applications could not be anticipated in creating these guidelines. Where there are questions of adherence to this document, such as use of an "off-the-shelf" design, always consult the responsible Ergonomics Department. Refer to SAE/USCAR-12 Wiring Component Design Guidelines for additional guidelines.
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SAE/USCAR-26
Test Procedure for Electrical Ground Attachments
This test procedure is intended to evaluate and/or validate electrical ground schemes for use on the body or chassis. There are two classes based on the expected environmental conditions. Exposed Grounds can be located anywhere in the vehicle (except on the powertrain) and is the class for which most schemes should be tested. Unexposed Grounds can only be used in the passenger compartment or trunk and as such are special cases.
This procedure as written is not intended for testing powertrain grounds where high temperatures and vibration levels may be encountered. These situations may require modifications to this procedure and are left to the Responsible Engineer to determine.
This specification does not specifically address validation of terminal to wire electrical crimps. Crimps are tested to SAE/USCAR-21
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USCAR 27
Specification for Testing Gas Discharge Light Source Subsystem
This specification is a general level subsystem light source specification that establishes test requirements of a Gas Discharge Light Source (GDLS) subsystem for use on passenger vehicles.
The completed test data to this test specification is intended to be provided to the OEM by the Tier one lamp set maker as part of the lamp assembly PPAP. Re-testing shall be required if any portion of the approved GDLS experiences a design, manufacturing or component change.
This document shall be applied to systems that meet the requirements for design, performance and validation established by government standards.
The subsystem is defined as the ballast, igniter and light source and shall be tested as a subsystem and considered one test sample for the entire test sequence. A failure of any component in the test sample shall constitute a failure of the entire sample. Substitution or replacement of only the light source shall be allowed during testing. Failure of the light source more than once in a tested system shall constitute a failure of the GDLS. If other manufacture's components are intended to be approved for use in the GDLS, then those possible combinations of components shall be considered a new GDLS and shall also be tested.
Additional testing may be required by individual OEM's to meet specific EMC, quality, reliability and durability objectives.
The following tests are to be performed under the following conditions:
- New light source (capsule) or ballast design
- Design or process change made to an existing capsule or ballast, which could affect the outcome of the test
- Completion of one calendar year as noted in the "ANNUAL TESTS" Table shown in the Appendix. (Note: Production process control data, collected at a shorter interval per an approved control plan, may be substituted if approved by customer's responsible engineer and purchasing representative.)
SAE/USCAR-28
Initiator Technical Requirements and Validation
This specification establishes the design, performance, and validation requirements for the initiator assembly used in airbag modules, seatbelt pretensioners and/or any other Electro-Explosive Devices (EED).
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USCAR 29
Automotive Grade Coaxial Cable Performance Specification
This document specifies dimensional, functional and visual requirements for Automotive grade coaxial cable. This material will be designated AG for general-purpose automotive applications or AG LL for low loss applications. It is the responsibility of the user of this cable to verify the suitability of the selected product (based on dimensional, mechanical, electrical and environmental requirements) for its intended application. It is the responsibility of the supplier to retain and maintain records as evidence of compliance to the requirements detailed in this standard.
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USCAR 30
Performance Specification for Automotive Universal Serial Bus (USB) Connection System
Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of any USB cable assemblies and associated connections that constitute the electrical connection systems between the consumer peripheral interface and the USB computer source in road vehicle applications. These procedures are only applicable to the USB connector and the cable. Unless otherwise specified, all of the tests listed in this specification are for both consumer and nonconsumer interface connectors.
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USCAR 32
New Finish Development Document
This standard lists variables that shall be investigated and reported as an initial investigation into new or revised surface finishes intended for use on fasteners. This standard provides instruction for producing a final report that will be used to determine if further investigation of a surface finish is justified. Further investigation may include tests and evaluations specific to an individual OEM prior to introduction/approval of the surface finish. The final report shall include the results, observations, and conclusions for all of the variables. The final report may be made up of several individual reports covering each variable. In all cases the laboratory performing the test, the test date and the report approver shall be included in the final report.
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SAE/USCAR 34
Specification for Testing Automotive Lamp Assemblies
The procedures contained in this specification cover the laboratory testing of Exterior Lamps for use in automotive road illumination. The following tests are intended to be run under the following conditions.
This document shall be applied to systems that meet the requirements for design, performance and validation established by government standards.
If other manufacture's components are intended to be approved for use in the lamp assembly, then those possible combinations of components shall be considered a new lamp assembly and shall also be tested.
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USCAR 35
Test Procedures for Evaluating Bolt-Load Retention of Magnesium Alloys
1.1 A bolt-load retention (BLR) test is a practical test to determine the bolt load of a fastener joint with time and at given temperatures. There are three types of BLR tests described in this standard, namely general-purpose test, design-purpose test, and screening material test. A general-purpose BLR test may be used for screening materials, while a design-purpose BLR test is usually used to verify the BLR behavior of a specific joint. The screening material test is an example of the general-purpose test for typical automotive applications.
1.2 The test procedures provides guidance in the following areas: (a) BLR sample and test fixture, (b) test fastener, washer and nut, (c) bolt-load measurement and data acquisition, (d) heating device, (e) initial loading, (f) baseline test, and (g) instrumentation of strain gages and calibration (see Appendix B). A design-purpose test procedure differs from a general-purpose test procedure mainly in the areas dealing with sample and fixture, test washer and nut, and initial loading.
1.3 This standard is intended to evaluate and/or validate BLR of magnesium alloys, especially cast magnesium alloys, for automotive applications. It is implied that the test samples mentioned in this standard are to be produced from casting processes but are not restricted to castings and magnesium alloys.
This standard is intended to evaluate BLR behavior during long-duration BLR tests. The effect of thermal cycling without holding the samples at high temperatures for a long period of time is discussed in Appendix C.
SAE/USCAR 36
Dimensional and Performance Specification for After-Market Gasoline Engine Oil Filters
This specification defines the dimensional and performance requirements for aftermarket spin-on oil filters intended for use on gasoline engines. Filters meeting this specification may also be suitable for use on some diesel applications.
Filters meeting these dimensional limits are intended to meet the oil filter fit and package requirements for engine and vehicle designs.
Filters meeting the performance requirements are intended to support OEM's recommended oil change intervals up to one year of time in service.
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USCAR 37
High Voltage Connector Performance Supplement to SAE/USCAR-2
Procedures included within this specification supplement are, when used in conjunction with SAE/USCAR 2, intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in high voltage (60~600V) road vehicle applications. These procedures are applicable to terminals used for In-Line, Header, and Device Connector systems with and without Shorting Bars.
This supplement applies to both sealed and unsealed connection systems.
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SAE/USCAR 38
Performance Specification for Ultrasonically Welded Wire/Cable Termination
IMPORTANT NOTICE: In any intended vehicle application, if the products covered by this specification are, or may be, subjected to conditions beyond those described in this document, they must pass special tests simulating the actual conditions to be encountered before they can be considered acceptable for actual vehicle application. Products certified by their supplier as having passed specific applicable portions of this specification are not to be used in applications where conditions may exceed those for which the product has been satisfactorily tested.
The Authorized Person is the final authority as to what tests are to be performed on his or her parts and for what purpose these tests are required. He or she is also the final authority for resolving any questions related to testing to this specification and to authorizing any deviations to the equipment or procedures contained in this specification. Any such deviation must be documented and included in the final test report.
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USCAR-40
Lead-Free Solder Validation Test Plan
This guideline is applicable to existing lead solder production products that will change to lead-free solder processes to meet the ELV Directive 2000/53/EC Annex II, exemption 8B requirements. This guideline is applicable to similar products used by multiple OEM’s that have the same manufacturing processes/equipment. The intent is to streamline the supplier’s environmental testing via common qualification to reduce timing, quantities, and costs.
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For questions concerning USCAR documents or the USCAR project, contact Nikki Ameredes at 248/273-2462; fax: 248/273-2494.. For questions concerning SAE’s Cooperative Research Program, contact Gary Pollak at 724/772-7196.
