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Multicoated steel materials including prephosphating, temporary organic coatings and Zn-rich paints are being developed as alternative to the conventional metallic coated steel materials in order to improve properties such as corrosion resistance as well as formability, weldability and paintability.

Mobile equipment manufacturers continue to be faced today with the ever pressing demand for increased productivity from their hydraulic machines. The on-off type of hydraulic control valves are not accurate enough and do not have the controllability required for increased production rates. The requirement is for valves that smoothly meter flow as well as control direction, without excessive power losses. Further, because of the continued emphasis on operating ease and flexibility of hydraulic system installation, there is need for simple and reliable remote controls that are compatible with existing hardware. This paper presents the performance requirements for remotely controlled mobile hydraulic valves, and describes how they are met by a new family of pressure-compensated proportional valves with six remote control options: mechanical (push-pull cable), hydraulic, pneumatic, electrical, fiber-optic, and radio.

The Honda NSX, made entirely of aluminum, introduces a concept of using chromium chromate as a method of chemical pretreatment. For other parts that contain a different type of metal, such as various parts of the chassis, a DACRO coating system as well as many other inventions are used. For the paint process itself, a new waterborne basecoat technology is also introduced to obtain a high-class appearance level for the NSX.

There are two well known basic concepts for achieving magnetic levitation of vehicles: one is based on electromagnetic attraction (EMA); and the second method is based on electrodynamic repulsion (EDR). In turn, each of these concepts have at least two variations (1, 2 and 3)1 This paper presents a third form of magnetic levitation known in the USSR as the Magnetic Potential Well (MPW) developed by Kozoriz (4), and in the West as Laithwaite's Magnetic River (14). The MPW effect is based on a dc circuit and exhibits characteristics whereby: the magnetic attraction force passes through a null, before the distance becomes zero, and changes to magnetic repulsion, as a function of interval separating a superconductive (SC) dc electric circuit and a second dc electro and/or permanent magnet, and/or two-wire dc line pair of infinite length.

Acoustic source identification is an important issue in both early and prototype validation stages of NVH design. OEMs and suppliers need to assess the entire description of vehicle noise emission, to understand and address interior comfort and exterior radiation issues. Today, none of the existing methods allow engineers to get a quick snapshot of sources contributing to the external pressure level affecting pass-by noise emission compliance, requiring long and arduous testing projects with & without physically masked components. A new acoustic imaging technique provides an important solution. The method is based on a microphone array. Like a camera, but unlike current holographic methods, the software delivers focused, near-realtime 2D colour snapshots and movies, corresponding to the sound pressure level at the region of interest. Typically, the entire side of a vehicle can be analysed during one pass-by run.

This paper discusses some aspects of durability tests in laboratory, justifying the necessity of a new procedure for data compression. Attention is paid to dynamic tests, with the presence of inertia forces. The new procedure is introduced, which uses concepts of fatigue due to vibration and signal analysis. The compression procedure is applied to generate a synthetic signal for the experimental stress test of an automotive component.

Japan National Oil Corporation (JNOC) has been tackling the technical research and development of natural gas conversion technology since FY1998 in collaboration with five Japanese private companies in order to aim at establishing the option technology to explore stranded gas reserves. The Syngas section of JNOC's GTL process applies the steam/CO2 reforming and the FT section employs the slurry reactor with Ru- or Co- catalysts. JNOC's GTL process is capable of utilizing CO2 contained in the natural gas and does not require any O2 supply. Namely, the characteristics of JNOC's GTL process in contrast to those of the existing ones using ATR or POX are (1) no use of the O2 plant, (2) no use of the CO2 separation unit, and (3) no use of the H2 conditioning unit. Such facility savings will bring about a remarkable reduction of the plant cost for its election and operation.

INTRODUCTION OF ALUMINIUM as a body construction material requires changes in part design such as added overcrowning, changes in pressing and assembly such as use of rope hemming, introduction of alkaline pickling for better results with welding, bonding, corrosion protection and use of wax when sanding. Changes in painting included the insulation of certain parts when EC-dipping and extensive corrosion testing to find optimum combinations of materials, cleaning and phosphating chemicals. Conventional corrosion-testing methods were found to give misleading results, especially for Al-alloys which contain copper.

We take the opportunity to present a recently established strategical partnership between ECCO Gleittechnik GmbH and FRIMECO Füllstoff Handels Ges.m.bH.. This co-operation allows us to present and market a new kind of fibrillized natural fibre for the Friction industry by combining ECCO's technical Know How in the field of natural fibres and FRIMECO's knowledge about the Friction Materials market.

A new process for a highly reliable ceramic substrate with electric circuit has been developed for power devices of automotive applications. The circuit conductor has high conductivity to accept a current of 10 to 200 Amperes, and has strong joining strength to ceramic substrates. The conductor is made of sintered copper powders with several kinds of diameters to get a porous structure, for reducing Young's modulus and thermal stress between the circuit conductor and ceramic substrate. Sintering shrinkage of the circuit conductor has been restrained, and joining strength to the ceramic substrates kept strong by an anchor effect. The copper circuit conductor realized electric resistivity of 2.3×10-6 ohm-cm, and coefficient of thermal conductivity, 290 W/mK. We have also confirmed superior reliabilities in the joining strength and conductivity by thermal cycling tests.

New efficient protection finish for magnesium die cast parts for automotive application, obtained by primer + application of paint by electrophoresis.

The corrosion of active metals such as magnesium and aluminum continues in spite of the recent development of more corrosion resistant alloys. Much of the corrosion occurs due to chloride ion attack aggravated by design problems that produce crevices and other corrosion prone surfaces. Many components made of obsolete alloys remain in service. In this paper basic protection schemes are reviewed for both magnesium and aluminum. Pretreatments and coating systems typically used are outlined with emphasis on problems at overhaul and reassembly. A novel coating primer/sealer process is described which provides a significantly more corrosion resistant surface for both magnesium and aluminum alloys. A mechanism for the operation of the coating film is offered; how it is combined with pretreatments to seal and prime the active metal surface is described. Data is supplied indicating corrosion resistance in salt spray tests, humidity tests and exposure to aerospace fluids.

In competitive markets the search of the differentiation is basic for the companies survival. That can be achieved through the new products development - NPD which is composed for five classic phases: sprouting of the idea, concept, validation of the concept, development and launching of the new product. Market successful new products can generate cost reduction and increments in market share and profit and, thus, Value Creation. This work analyses the Value Creation of the Brazilian automobile industry due to the influence of the development of new products under the perception of the managers of this industry. Results demonstrate to have a positive relation.

The performance and cost gap between conventional rubber mountings and hydraulic damped mountings will be closed by a Pneumatic Damped Rubber Mount. Mainly for small size vehicles this concept offers a suitable compromise for shake and acoustics. Conventional hydrobushes for engine mounting systems have some general problems such as poor endurance life and acoustic performance. A new Hydrobush Design overcomes these difficulties by a multi material design. Certainly, more complex systems require switchable hydraulic damped mounts. In particular, Diesel Engines often need better isolation at idle operation. An Electronic Switchable Hydromount has been developed and checked successfully in different vehicles. Finally, active technology offers a huge potential to influence vehicle NVH performance.

Vehicle front suspension systems are designed to achieve the best possible compromise between comfort and handling. Some inputs into the system are isolated by parts that link the suspension components to the frame. This presentation addresses two of these connector applications. They are the suspension arm bushings and the upper strut cushion. Conventional products as well as new innovative C.P.I.O. approaches are discussed. The TORSIDYNE slip bushing concept is applied to suspension arms. This approach replaces torsional rubber return with easy rotation while offering flexibility in the areas of radial, axial and conical rate. The ATADYNE principle is discussed for usage in upper strut mount applications. In addition to other features, it maintains a variable variable vertical rate regardless of the mount operating position.