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The extrusion of zinc alloys, with special reference to zinc-titanium alloys, is described. Parameters for this process are defined. The excellent tensile and creep properties obtained in a typical extruded zinc-titanium alloy are presented. Extruded zinc with a quality copper-nickel-chrome plated finish offers a new approach to the production of automotive trim and of similar products.

Many papers have been written for SAE on electrochemical metallizing, a modern term for “selective” or “brush” plating. These papers have dealt primarily with the aerospace industry, including the use of non-embrittling cadmium LHE® coatings for corrosion protection on aircraft. Shadowed by 30 years of successes in the aerospace industry, electrochemical metallizing corrosion protection in the automotive industry is often overlooked. Specifically, the use of selectively applied zinc coatings for corrosion protection on wheel hubs during manufacture has proven integral at several European automotive manufacturers. In the past, environmental conditions have corroded both the hubs and wheels of automobiles. Quite often the corrosion is in the microscopic gap between the hub and the wheel, which over time causes the wheel to seize and prevents removal. This has been frustrating to both stranded motorists and shop mechanics.

AS PART of its continuing research to improve the die casting process, International Lead Zinc Research Organization, Inc. has prepared a computer program, “Computer-Aided Design for Zinc Die Casting Dies,” which will enable a die caster to design the metal flow system for a die within a matter of minutes—simply and more accurately than ever possible, previously. It is helping convert what has been an art into a science.

The role of zinc die castings in the materials marketplace has changed significantly in the last generation. In response to a shift in the available market, the industry has made major advances intended to improve competitiveness in both traditional and non-traditional areas. Better efficiency and performance have been achieved by the application of new methods and technologies. The ZA alloys, introduced to die casting during the last decade, have markedly expanded the capabilities of both zinc and the die casting process. This paper presents a review of several zinc die castings used in automatic applications.

Zinc die casting products and metal casting processes continue to evolve for the benefit of end users. Through cooperative global research programs continuous improvements are still being made to the broad range of excellent mechanical properties, easy castability and the wide choice of finishes available for zinc die castings. Recent advances will be highlighted with case histories specific to automotive applications.

Because of the drastic chilling involved in die casting and the fact that the solid solubilities of both aluminum and copper in zinc change with temperature, these alloys are subject to some aging changes, one of which is a dimensional change. Both of the alloys undergo a slight shrinkage after casting, which at room temperature is about two-thirds complete in five weeks. It is possible to accelerate this shrinkage by a stabilizing anneal, after which no further changes occur. The recommended stabilizing anneal is 3 to 6 h at 100 °C (212 °F), or 5 to 10 h at 85 °C (185 °F), or 10 to 20 h at 70 °C (158 °F). The time in each case is measured from the time at which the castings reach the annealing temperature. The parts may be air cooled after annealing. Such a treatment will cause a shrinkage (0.0004 in per in) of about two-thirds of the total, and the remaining shrinkage will occur at room temperature during the subsequent few weeks.

Traditional and new zinc-based casting alloys for functional and decorative applications are reviewed. Their compositions and standard alloy specifications are described, and recommendations for casting process selection and prototyping of applications are offered. The information presented shows the versatility achievable with zinc alloys. It is aimed at helping part designers make the most effective use of zinc for their component requirements.

High damping capacity materials are useful in attenuating vibrations in mechanical structures such as functional automotive bracketry. The intrinsic damping properties of zinc alloys have only recently been systematically measured. Low and high frequency damping experiments have been conducted on die cast zinc alloys. and damping capacity has been measured as a function of temperature at high frequencies. The alloys show excellent damping properties over the range from 5 Hertz to a few hundred Hertz. for service applications from 40-80°C (104-176°F).

SIMILAR SPECIFICATIONS—UNS Z33521, former SAE 903, ingot is similar to ASTM B 240-79, Alloy AG40A; and UNS Z33520, former SAE 903, die casting is similar to ASTM B 86-76, Alloy AG40A. UNS Z35530, former SAE 925, ingot is similar to ASTM B 240-79, Alloy AC41A; and UNS Z35531, former SAE 925, die casting is similar to ASTM B 86-82a, Alloy AC41A.

The ZA series of zinc alloys produce high strength die castings with the same cast-to size capability as the well proven SAE 903 alloy. The enhanced properties have been utilised in the two engine components described in this paper. ZA 27 has been used for the tooth belt drive camshaft pulley of a motorcycle engine and ZA8 has been used for the temperature resistant housing of a car ignition distributor.

This specification covers a zinc alloy in the form of die castings.

This specification covers a zinc alloy in the form of die castings.

This specification covers a zinc alloy in the form of die castings.

This paper describes the testing of a waste management system designed and fabricated for use in a space vehicle. The system provides for the collection and inactivation of urine, feces, emergency diarrheal disorders, vomitus, and debris; the volumetric determination of each micturition; and onboard storage of the inactivated wastes within the waste management system compartment. The zero-gravity test program conducted in a KC-135 aircraft provided the primary verification of the performance of the waste collection and urine volume determination functions prior to actual space flight. The test hardware simulated the actual system to a high degree of fidelity with respect to operational characteristics of the airflow required in collection, mechanical functions and system pressure differentials, in order to minimize simulation errors.

This study aims at a new concept for a fast catalyst light-off in combining a latent heat storage with a catalyst. The arrangement of a latent heat storage device into the exhaust system offers significant benefits for the catalyst light-off. Different arrangements have been examined. The first arrangement, called the sequential arrangement, comprises a latent heat storage device and a subsequent catalyst. This offers a significantly faster heat up of the catalyst compared to the standard arrangement. By that emissions during the cold start phase can be significantly reduced. The setup of the latent heat storage device is designed for a high heat transfer between storage material and the exhaust gas. A second integrated arrangement of a latent heat storage and a catalyst into one common substrate has also been set up and investigated. The main advantage of this arrangement is that the catalyst itself is kept on its operation temperature during the engine off time.

Recent developments in the commercialization of mobility services have brought unprecedented connectivity to the automotive sector. While the adoption of connected features provides significant benefits to vehicle owners, adversaries may leverage zero-day attacks to target the expanded attack surface and make unauthorized access to sensitive data. Protecting new generations of automotive controllers against malicious intrusions requires solutions that do not depend on conventional countermeasures, which often fall short when pitted against sophisticated exploitation attempts. In this paper, we describe some of the latent risks in current automotive systems along with a well-engineered multi-layer defense strategy. Further, we introduce a novel and comprehensive attack and performance test framework which considers state-of-the-art memory corruption attacks, countermeasures and evaluation methods.

Increasingly stringent emission levels require better quality facility gas supplies to enable more precise measurements at low levels and reduce variation in test results. The transient and steady state quality of the “zero gas” used in analyzer calibration will directly affect the level of the readings, while variation in the “zero gas” over time will increase the number of tests needed to meet statistical requirements. Facility zero gas supplies for air and nitrogen, at a minimum, require careful evaluation to confirm that the required gas quality is delivered to the test equipment for the desired instrument accuracy. To move from LEV or ULEV to SULEV analysis, a change in methodology of zero gas generation, delivery and handling may be needed to achieve the desired measurement accuracy and repeatability. Traditional tubing, fittings and handling methods can not only limit the possible gas quality, but also contribute to variation.

This paper discusses the advantages and problems associated with the use of “passive” liquid containment systems that utilize liquid intermolecular forces for propellant orientation in reduced or zero gravity environments. Liquid orientation is required to provide reliable engine restart and tank venting operations of space vehicle propulsion systems. Various liquid containment system concepts, and associated design criteria, are presented and general problem areas of interface stability, liquid slosh, and effects of thermal energy are described. Descriptions of present and planned test facilities designed to provide reduced gravity environments and extended time durations are included. It is concluded that additional design criteria in the problem areas discussed must be obtained before “passive” liquid containment systems can replace systems now used in reduced or zero gravity environments.

(From Standards Proposal No. 2358, formulated under the cognizance of the EIA Quality and Reliability Engineering (QRE) Committee.)

Conventional attribute sampling plans based upon nonzero acceptance numbers are no longer desirable. In addition, emphasis is now placed on the quality level that is received by the customer. This relates directly to the Lot Tolerance Percent Defective (LTPD) value or the Limiting Quality Protection of MIL-STD-105. Measuring quality levels in percent nonconforming, although not incorrect, has been replaced with quality levels measured in parts per million (PPM). As a result, this standard addresses the need for sampling plans that can augment MIL-STD-105, are based upon a zero acceptance number, and address quality (nonconformance) levels in the parts per million range. This document does not address minor nonconformances, which are defined as nonconformances that are not likely to reduce materially the usability of the unit of product for its intended purpose.