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The properties of Cold drawn electric resistance welded, as drawn (CEW-AD) tubes and Electric resistance welded (ERW) tubes are vastly different. Deformation resistance of ERW tube is less than half that of CEW-AD tube, hence not preferred for structural applications, common practice being the use of CEW-AD tubes for Chassis cross members in vehicles. A new cost effective high strength ERW tube was developed which has been proved to be superior to the currently used CEW-AD tubes in terms of mechanical properties, formability, consistency and uniformity of the properties over the tube length. The newly developed tube through use of special micro alloy grade in ERW has made it possible to eliminate some of the manufacturing processes like annealing, phosphating, cold drawing etc. which has led to considerable cost saving.

A large number of metal cutting inserts are used in the manufacturing of automobile parts. These are made from hard metals like Carbide, Ceramic, Cermet, PCD and CBN. Since making of these hard metal inserts involve a high amount of energy in addition to natural resources namely Titanium, Tungsten, Cobalt etc, any attempt made therefore for reusing of the used up inserts will benefit environment because this reuse will lower down the demand on natural resource. Reuse can be done in a number of ways [ 1 ]. Many of these recycling techniques involve removing the dull portion developed during the first use by re sharpening [ 2 ]. A different approach is being suggested here in which used up inserts can be used directly. This approach leads to use of the unused cutting edges /corners of the insert without any re sharpening. Thus the cost of machining becomes half of the original cost or even more depending on the application for reuse.

Today's automotive industry demands high quality component as well as system designs within very short period of time to provide more value added features to customers on one hand and to meet stringent safety standards on the other. To reconcile economy issues, design optimization has become a key issue. In the last few decades, many OEMs took to analytical tools like Computer-Aided-Engineering (CAE) tools in order to decrease the number of prototype builds and to speed up the time of development cycle. Although such analytical tools are relatively inexpensive to use and faster to implement as compared to the costly traditional design and testing processes: however, there are many variables that CAE tools cannot adequately consider, such as manufacturing processes, assembly, material anisotropy and residual stresses. Therefore, still smart measuring and testing techniques are required to substantiate the CAE results.

IC Engine manufacturers are constantly in pursuit of better sealability of cylinder head and engine block interface for meeting performance and durability targets. In order to overcome variation in torque - tension characteristics of cylinder head bolt because of friction variations, yield based clamping are being extensively adopted. Current study is done on torque - tension characteristics of a cylinder head bolt with a controlled quality. The paper enumerates the experimental setup representing a sub 1 liter all aluminum engine's head-block joinery. Studies on torque - tension characteristics of cylinder head bolt and the effect of sealing interface using a cost effective single layer steel gasket are being discussed in the paper. Subject work has led to a successful implementation of angular torque parameters on head bolts to meet functional and durability targets.