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Modern automotive transmissions contain copper and copper alloys in the form of washers, bushings, brazes and electrical components. Corrosion that occurs with any of these components especially with electrical contacts can result in a malfunction of the vehicle control systems and loss of vehicle drivability. The compatibility of transmission lubricants with copper and copper alloys is an increasingly important consideration in the design of new additive technology. Traditional methods for monitoring corrosion processes and mechanisms in real time can be both time consuming and challenging to interpret, especially when evaluations at multiple temperatures are required. This work challenges some of the industry-held beliefs around lubricant additive corrosion processes, especially at elevated temperature (>130 °C).

Peugeot used the 2016 Paris Show for the public launch of the 3008 and 5008 models, now re-defined as SUVs. Both models use the PSA Efficient Modular Platform 2 (EMP2).

In the near future the effort on the development of exhaust gas treatment systems must be increased to meet the stringent emission requirements. If the relevant physical and chemical models are available, the numerical simulation is an important tool for the design of these systems. This work presents a CFD model that allows to cover the full range of applications in this area. After a detailed presentation of the theoretical background and the modeling strategies results for the simulation of a close-coupled catalyst are shown. The presented model is also applied to the oxidation of nitrogen oxides, to a diesel particle filter and a fuel-cell reformer catalyst.

In the American Automotive Industry, the trend as we enter the 80's is clearly to down-sized cars. Every manufacturer has had to develop and introduce lighter cars with low fuel consumption; some are already in production and offer the American public domestic vehicles which more than compete with the imports which have so dominated the news in recent years. The world-wide energy situation and the initiative of the United States Government to mandate a dramatic series of yearly drops in fuel consumption by means of the Corporate Average Fuel Economy rulings, has helped to further accelerate the move to smaller cars, which are more economical to own and maintain. In the 1976 Chrysler broke new ground with Omni/Horizon. GM was next in 1979 with its well-received X-Cars. 1981 Model Year saw the eagerly awaited introduction of the Chrysler K-Car and Ford Escort/Lynx.

A new piston ring face coating has been developed in an effort to extend the life of internal combustion engines. The molybdenum chromium carbide composition was determined through the use of the Taguchi method, Design of Experiments. Engine tests show the material to have improved piston ring and bore wear resistance over many similar coatings used in production. Comparisons of ring-bore wear data are made from engine tests incorporating hardened and non-hardened bore turbocharged diesel engines. Bench tests provide comparative friction and wear data.

This paper briefly reviews the progress in reducing emissions over the past eight years through improved piston ring designs and compatible facings. The newer emissions control laws for 1976 require considerable further work in reducing emissions from every possible source. The authors discuss the green engine effect and suggest the use of reduced-friction piston rings to yield assembly-line emissions test results more nearly representative of the emissions from an engine after extended break-in running. To reduce oil contamination for the purpose of conserving natural resources by extending oil change intervals and also to reduce emissions, the writers propose the use of zero blowby piston rings and discuss a novel design. New piston ring facings may also play a part in improving durability and compatibility when ashless oils are specified and when the piston rings must be mounted at the top of the piston.

A new telemetry system has been developed for temperature or strain measurements on a spherical joint piston. The system includes a piston mounted signal multiplexer and transmitter. A patented, piston mounted power generator operates in conjunction witii a modified cylinder liner. The telemetry system is robust, having high inertia load capability and high environmental temperature operating capability. The telemetry system was installed and operated on an engine motoring test rig. Temperature signals were transmitted at engine speeds from 400 rpm to 2100 rpm. Over 100 hours of high engine speed testing with oil sump temperatures up to 122°C were completed.

A new plasma generator has been developed for plasma spraying. The generator allows operation up to 80 kW power levels with a single gas: Argon. The embodied technology incorporates innovative arc stabilization coupled with closed loop voltage control. This results in a better characterized plasma plume. The ability to tailor the plasma plume through independent control of plasma gas flow, arc voltage and arc current allows the application of repeatable high quality coatings.

This paper describes a new plastic coloring and forming system. The system greatly reduces the time and amount of raw materials necessary for color changes, and eliminates the need for manual cleaning during a color change. This system is well-suited for small-lot production with frequent color changes, as well as for automated production systems. The system is being used by auto parts makers, and is practical in a variety of other fields involved with the coloring and forming of plastics.

This paper will describe the commercial drivers and a new technical solution for providing Satellite TV to moving vehicles in a form factor and at a price point that will allow for application to virtually any size vehicle. The paper will further describe a new video delivery service concept (tentatively described as T7 for the purpose of the paper) that will provide a fast to market, low capital expenditure, and fully scalable platform specifically designed for use in mobile vehicle applications.

Catalyzed diesel particulate filter systems have now been successfully introduced and implemented in Europe. In the meantime, automotive manufacturers are working on the second generation of catalytic filters with the aim of reducing the overall system costs. In particular savings in precious metal costs are focussed by the use of highly-active catalysts which are stable at high temperatures. A possible approach here is the implementation of oxidation catalysts and catalytically coated filters based on platinum and palladium. In this context, the functio-nality of platinum/palladium-based, catalyzed filters was investigated by numerous measurements on a synthetic gas and an engine bench as well as by vehicle tests on a roller dynamometer. The HC/CO oxidation activity, the poisoning resistance towards sulfur and the desulfurization capability, the exothermic behaviour due to the conversion of subsequently injected hydrocarbons and the NO2 formation potential were examined in detail.

Competition in Automotive Market is driving the need for more time - and cost - effective testing methods. In the fatigue life analysis of new passenger and commercial vehicle designs, laboratory testing through servohydraulic equipment plays a very important role. In DaimlerChrysler do Brasil, the Durability Test Laboratory represents an important basis to assure high endurance reliability for all kinds of our commercial vehicle applications. In order to respond to the above mentioned testing tasks, this paper will focuse what we call our “New Policy of Durability Tests for Commercial Vehicles”, based on development of simple and low cost Road Simulators, fully dedicated and customized to testing of vehicle components and chassis. Experimental results as well as other data related to consumption of laboratory's: area, utilityes, pressurized hoses and test time, will be used in order to illustrate advantages and disadvantages of the new testing resource.

Polychloroprene rubbers have well balanced properties, but they lose flexibility at low temperatures and are not sufficiently resistant to high temperatures. Propylene oxide -epichlorohydrin -allyl glycidyl ether terpolymer is no less oil resistant than polychloroprene rubbers and has a −50°C brittle point without using plasticizers. With a sulfur vulcanizing system, the terpolymer's vulcanizing curve is snappy. With the 2.4.6 -trimercapto-s-triazine cure system, good heat resistance and low compression set vulcanizates are obtained. Terpolymers reinforced with silica have high tensile strength and good flex life.

This paper describes the development and commercialization of a new polymer blend technology. This technology is a radical step forward resulting in the most synergistic thermoplastic blends available today. The full chemical resistance of crystal line materials is coupled with the outstanding dimensional stability of amorphous plastics. The material is called GTX. This paper describes the mechanical properties of GTX for use in exterior body applications.

The multitude of megatrends influencing today's auto industry has clearly defined the need for new high performance thermal plastic composite materials that will extend product life under harsh conditions. In response a new family of nylons from DuPont which combines the ease of processing of conventional nylon resins with groundbreaking levels of resistance to chemicals, hot air, oil and coolant were developed. Comprehensive research shows that, in comparison to traditionally stabilized nylons, the lifetime of components can be significantly extended. This, along with other benefits, such as low warpage and an excellent surface appearance, make the new polyamides ideal for a range of applications, which to date have been reserved for metals or considerably more expensive high-performance thermoplastics.

The market has recently required the bearings to operate under intermittent or occasionally boundary lubrication conditions through requirements guided basically by CO₂ reduction: flex-fueled engines, stop-start operation, specification of low viscosity oils, extension of high speed regimes with low stiffness conrods and crankshafts. The sensitivity of the oil film rupture, higher loads and the robustness of operation required the development of low friction coatings or overlays with improved wear resistance. MAHLE response to these requirements has been addressed through a newly developed product assigned as polymer-coated bearing. The polymeric overlay has a proprietary low friction solid blend and it is sprayed onto premium bimetallic bearings. In this paper it is shown that these bearings run at lower temperature, with lower friction and can support higher loads than the conventional bimetallic bearing.

Worldwide emissions standards are becoming increasingly rigorous, and this leads to more complex engine demands. Several new PCU (Power Cell Unit) technologies are being applied to cope with these demands. This means engine parameters are changing, e.g. higher EGR (Exhaust Gas Recirculation) rates, higher PCP (Peak Cylinder Pressure), lower viscosity oils, higher oil contamination and soot. Therefore the operating conditions for the bearings have drastically changed, leading to an environment prone to seizure occurrences. There is a clear demand for seizure resistant bearings motivated mainly by the increased engine complexity described above. Therefore for HDD (Heavy Duty Diesel) applications the PCU robustness should not be compromised also in terms of wear and fatigue resistance. The polymeric coating developed by MAHLE was applied over a sputtered layer and has demonstrated to be a suitable solution to attend to the application demands.

In recent years plastics have been finding increasing application in underhood performance parts due to good thermal performance, weight reduction, cost savings, and design flexibility. Downsized cars with lower hood lines and smaller engine compartments as well as an increasing dependence on sophisticated electronics have placed stringent demands on the performance of plastic components. Automotive materials have an increasing demand for higher heat, humidity, and chemical resistance. Polymethylpentene (PMP) is a semicrystalline “engineering polyolefin” which melts at 240°C. It has a density of 0.835 g/cc, one of the lowest of all polymer resins. PMP also exhibits high optical clarity, good thermal and chemical resistance, outstanding electrical properties, and good processability. Mechanical properties at room and elevated temperatures are improved by the addition of glass reinforcement.

A new family of homogeneous polyolefin copolymers can be produced by Dow's INSITE* Technology. These ethylene/octene based, designated as polyolefin plastomers (POP) and polyolefin elastomers (POE), exhibit many unique physical and mechanical properties1,2,3,4 due to their narrow composition distribution (i.e., comonomer distribution and molecular weight distribution). In addition, the INSITE* technology also allows for the production of homogeneous copolymers with a controlled level of long chain branching (LCB) along the polymer backbone. This unique molecular structure results in many improved rheological properties5, such as enhanced shear thinning and high melt elasticity, and improved polymer melt processability6. Additionally, the unique rheological properties of the INSITE Technology polymer (ITP) also provide improved dispersion capability in rubber modified polypropylene (PP) blends.