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Virtual casting improves powertrain design As designers continue to look for ways to cut weight and increase performance, casting simulations are helping optimize designs through faster, more accurate predictions of the casting process used to create key components. Horse racing America's pony cars are a favorite of racers and fans alike, so racing them against each other is natural. SAE 2015 World Congress Preview Tech trends and exhibitor products are highlighted. Tech trends and exhibitor products are highlighted in this special section, which features an exclusive interview with Honda R&D America's Jim Keller. Replicating the racing experience Professional driving simulators can be successfully exploited to shorten the traditional design-prototype testing-production process relative to a new racecar.

Balancing GDI fuel economy and emissions Will OEMs have to adopt gasoline particulate filters to comply with stringent new emissions regulations? Top engineers discuss current developments. Cameras look to go the distance Automakers seek vision systems with greater distances, improved reliability, and more functionality, thanks to ruggedized complementary metal-oxide semiconductor technologies. Mixing metals Cadillac pursues aluminum/steel mix for new CT6 luxury sedan, leading to advances in body assembly.

2016 Malibu sheds 300 lb, adds new hybrid system More wheelbase, style, fuel economy, and comfort aim to move GM's volume midsize sedan from the sidelines to the fast lane. Lighter, more powerful 2016 Honda Pilot The third-generation SUV gets a sleek new look and plenty of slick technology for enhanced performance and safety. 2016 Mazda MX-5 stays true to its roots Mazda engineers give the industry a lesson in getting more from less. 2016 Land Rover Discovery Sport spearheads more efficient Land Rovers JLR's space-efficient, flexible SUV moves to JLR's new Ingenium modular engines. Audi chooses high technology, cautious design evolution for new A4 In addition to lighter weight and significant improvements in efficiency, the new car employs plenty of technology and driver support.

Driving EVs toward lower cost The race is on to reduce battery and electric-drive systems costs while improving efficiency. Seeking ways to make better computer crashes New models and simulations help improve safety as software and hardware provide more realism to iterate designs more quickly. Evaluating aluminum bonds Adhesively joined aluminum alloy sheets present challenges that steel-adhesive joints do not. Ford researchers present a modified technique to inspect Al-adhesive joints in lab and production environments. Leading the attack on engine pumping losses Cylinder deactivation delivers real-world fuel economy gains, helping vehicles to meet and exceed their sticker numbers. That's why the downsized/boosted guys now want it on their engines.

Active in aero Several automakers-notably Mercedes-Benz and Audi - used the Frankfurt Motor Show stage to reveal sleek vehicles that aggressively employ active aerodynamic elements and other advances to reduce drag. Composites permeate inside and out Composite materials are gaining popularity for both unseen structural components and for exterior eye candy. Powertrain testing: coping with complexity With increasing use of electrical components to extend the performance of conventional combustion engines, powertrain development has never been more complicated. The good news is that test and development engineers are harnessing advanced simulation techniques and computer processing to develop the most efficient and fun powertrains ever. Can ads help in vehicle-to-vehicle rollout? Porsche unveils new downsized, boosted 3.0-L boxer six. Johnson Controls, Faurecia envision interiors for autonomous driving. Jaguar enters performance crossover SUV segment.

Diesel gets a promotion at SAE Clean Snowmobile Challenge The main rules change for the 2015 season is creation of a new engine category (diesel), the event's organizer notes in providing an overview of the SAE Collegiate Design Series competition. Wisconsin-Stout puts faith in gearbox redesign for Baja Blue Devil Racing Team believes packaging and durability advantages more than offset weight and low-end-torque penalties. Test cell at Kansas University does double duty Single-cylinder engine test cell designed for research into biodiesel also serves as an instruction tool for students. University of Michigan students have hand in Volt battery reliability Technology co-developed by U of M monitors the quality of welds used in the joining of Chevy Volt battery cells.

Rotary SI/CI combustion engines: A thing of the future? The internal combustion engine enjoys widespread use as an inexpensive and reliable power conversion system. While piston engines date back 150 years, various alternative engine architectures and cycles have been considered. Aftertreatment comes with challenging diagnosis Diagnosing engine and aftertreatment systems is forcing design teams to look at new ways to diagnose problems over long vehicle lifetimes. Taking on NVH reduction techniques A look at the enhanced durability benefits obtained by changing the polymer composition, manufacturing methods, and design optimization of a powertrain mount for an off-highway vehicle.

Making sense of autonomy Industry offers a range of sensors that will free humans from many tasks while also improving reliability, though devising strategies that meet demanding requirements without breaking the bank is no easy challenge. Life-cycle planning-Design and calibration for ultimate efficiency The ultimate power of Big Data technologies relies on the implementation of new strategies. Unlike a traditional engine calibration process, in which only calibration test data and model simulation data are used, multiple source data introduced into the adaptive engine calibration process contributes to efficiency and cost reduction. The complicated future of off-highway engines Developing an optimum engine is getting tricky now that the European Union has established a Stage V for off-highway engines, and the U.S. has not. What effect will this have on future engine designs?

Hydraulics still in control of off-highway needs Engineers continue to master electronic controllers and software to help systems manage engine speeds and boost efficiency, to the ultimate benefit of both OEMs and end-users. Off-highway calibration challenges-big and complex As the final set of Tier 4 regulations kick in for engines greater than 750 hp (560 kW), calibration efforts must contend with complex engine and aftertreatment systems. Engine manufacturers and service providers deal with this complexity, but does it need to be so? DEF delivery modelling for SCR systems Researchers characterize a 0-D model of a urea delivery module, oriented to model-based control and to the simulation of the system response to fault injections finalized to diagnosis validation.

Executive Viewpoints Off-highway industry executives from companies such as BorgWarner, Perkins, Cummins, and Danfoss reflect upon challenges inside, and outside, the industry, and what technologies, innovations, and strategies will need to be implemented to thrive into the long-term future. 16th Annual Product Guide Top products from throughout the industry covering technologies such as Powertrain & Energy, Hydraulics, Electronics, and Testing & Simulation.

Electronic Warfare Next Generation FPGAs for Electronic Warfare Systems Materials: Composites Managing the Impact of Nanomaterials in Aerospace Manufacturing Aerospace Materials/Manufacturing Turbine Flow Meters Alternative Power Sources Designing a Power Generation System for a More-Electric Aircraft

Seeing the Light Achieving Full-Color, Day or Night Readability for Flat-Panel Displays Multiple Node Networking Using PCIe Interconnects PCI Express (PCIe) interconnects, and how they can be used to support multiple node low latency data transfers over copper or optical cables, is gaining momentum in embedded computing solutions. Zero-Emissions Electric Aircraft Theory vs Reality Analyzing Radar Signals With Demodulation Combining Software and Hardware for Highly Specialized Multichannel Spectrum Monitoring Advanced Thermal Management Solutions Thermoelectric Cooling Thermal Ground Planes Thermal Management of Laser Diodes The Effect of Substrate Emissivity on the Spectral Emission of a Hot-Gas Overlayer Process Approach to Determining Quality Inspection Deployment Experimental Setup to Assess Blast and Penetration-Induced Secondary Debris in a Military Operations in Urban Terrain (MOUT) Environment Non-Contact Circuit for Real-Time Electric and Magnetic Field Measurements

Achieving Performance Advantages in Unmanned Systems Unmanned Vehicle Systems (UVS) are reaching new levels of functionality and performance, and it's not just for air vehicles either. COTS Embedded Systems and Link Budgets The days of proprietary embedded computing systems in military systems are numbered. Custom Designing Enclosures Using 3-D CAD Modeling Due to the advancement of 3-D computer-aided design software, enclosure manufacturing is not what it used to be. Technology advances industry. Fiber Optic Multi-Sensing Platforms Enabling Innovation Across Aerospace Organizations RECAT Wake Turbulence Recategorization New Concept for Improving the Performance of Electrically Small Antennas Microwave Radiometer for Advanced Nanosatellite Control Systems Secret Sharing Schemes and Advanced Encryption Standard SIPHER: Scalable Implementation of Primitives for Homomorphic Encryption Using Mathematics to Make Computing on Encrypted Data Secure and Practical

UAV Technology Using SWaP-C Reductions to Improve UAS/UGV Mission Capabilities UGV Technology Designing Rugged Computing Platforms for UGVs UUV & Robotics Technology Bi-manual Dexterous Manipulation for Maritime Explosive Ordnance Disposal UUV Technology Applying UUV Advances to Safeguard Harbors and Littoral Waters Robotics Technology Designing a Robot to Counter Vehicle-Borne Improvised Explosive Devices

Digital Design Tools Simulating Thermal Expansion in Composites with Expanded Metal Foil for Lightning Protection Rugged Computing Designing VME Power Systems with Standard Modules Optical Sensors Optical Ice Sensors for UAVs Rotorcraft Technology Rotorcraft Icing Computational Tool Development RF & Microwave Technology Curled RF MEMS Switches for On-Chip Design: Design Software Supports BAE System's Mixed-Signal Chip Design

Defying the disruptors and driving innovation Four top engineering executives discuss how their "traditional" companies are finding new technology opportunities and business growth amid the start-ups-and are even doing some disrupting themselves. Preparing for a 48-volt revival The quest to improve fuel economy is not waning, nor is the desire to achieve higher mpg through the use of just the right lightweight material for the right vehicle application. Additive manufacturing enhances GTDI pistons Selective Laser Melting may help manufacture future gasoline-engine pistons with enhanced heat-transfer properties and reduced weight.

Special report: Lightweighting Uncovering the next actions in the industry's grand mass-reduction campaign. CAE's next leap forward With 3D simulations skyrocketing, engineers are looking forward to highly-optimized toolsets to keep pace with complexity. SAE Convergence 2016 Preview Meet the disruptors, network with peers and learn about the latest tech solutions that are rapidly changing the auto industry. "Military-grade" aluminum Jaguar, Exa say simulation to eliminate prototypes by 2020 OEMs expand testing of FEV variable-compression ratio engine Growth of FCVs and EVs tied to infrastructure Bolt EV seat design cuts weight, delights tall passengers Rolls-Royce reveals a Vision of its future Volvo bets on new PowerPulse, not 48V, to attack turbodiesel 'lag' SEAT to spearhead VW's new platform and 48V technology Dr. Jay Baron of CAR discusses vehicle lightweighting and predicts the outcome of the crucial CAFE mid-term review.

Thought leadership at WCX17 Magna's CTO talks innovation and disruption at WCX17, the newly rebranded SAE World Congress. Patton's new campaign As new SAE International President for 2017, Doug Patton will advocate STEM, "cultivation" of prospective young engineers. New EEAs for the connected, autonomous future OEMs and their Tier-1 partners are revamping vehicle electronic and electrical architectures with "über brain" central computers and real-time Ethernet to feed tomorrow's data-hungry cars and trucks. Bridging the power gap with 48 volts New 48-V technologies are poised to arrive in volume to help meet CO2 regulations and satisfy the "vampire" power demands of new electrical subsystems and accessories. Autonomy, connectivity headline the 2017 Consumer Electronics Show The automotive component of CES expands as global anticipation for automated driving and enhanced connectivity intensifies. Editorial: Vital Transformation Supplier Eye The impact of shifting to the 'softer' side.