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This work aims to develop a PA6 nanocomposite with glass fiber (GF) and graphene nanoplatelets (GNPs) focusing on automotive parts application. Polyamide 6 is a semi-crystalline polymer that exhibits high fatigue and flexural strength, making it viable for rigorous applications. Along with the improved electrical, mechanical, thermal, and optical performance achieved in PA6 and GF-based nanocomposites, they can fill complex geometries, have great durability, and are widely utilized due to their capacity of reducing the weight of the vehicle besides a cost reduction potential. The glass fiber is a filamentary composite, usually aggregated in polymeric matrices, which aims to amplify the mechanical properties of polymers, mainly the tensile strength in the case of PA6.

Manufacturing processes impact many factors on a product. Depending on the selected method, development time, part performance and cost are affected. In the automotive sector, there is a growing demand for weight reduction due to the advent of electrification and the greenhouse gas emission regulations. In addition, geometric complexity is a challenging factor for the feasibility of mass production of parts. In this scenario, plastic materials are a very interesting option for application in various vehicle parts, since these materials can be molded by injection, vacuum forming, among others, while maintaining good mechanical properties. Almost a third of a vehicle’s parts are polymeric, making the development of these materials strategic for car manufacturers. This article investigates the impact of the presence of fiberglass in a thermoplastic automotive body part.

Polyurethane (PU) foams are versatile in automotive applications for sound absorption, due to their superior acoustic-absorbing properties, vibration damping and robustness, and seat cushioning products due to their easiness of manufacturing process and cost-effectiveness. In recent studies, micro- and nano-particles were used to improve sound absorption efficiency, these fillers help to form interconnected pore structures in the foam matrix, and this interconnection of pores is advantageous in dissipating heat generated from wave friction with the air. Some of the micro- and nano-particles used are natural fibers (like cellulose, fir, palm), silica, clay, graphene and derivatives, zeolite, and others. This review is an overview of recent advances in the incorporation of fillers in PU foams and the influence they have on the sound absorption capacity of the foams.

Steel represents more than 50% of weight in vehicles, being more susceptible to corrosion processes. Corrosion studies in these components are of great industrial and economic interest, and anticorrosive coatings with efficiency of superior protection is still a relevant area in materials research. Paintings from inorganic and organic hybrid compounds have been used to produce more effective and efficient coatings. Among polymeric coatings, epoxy resin is considered one of the most used anticorrosion coatings, mainly due its excellent protective properties. High barrier level is reached by reinforcing the coatings with inorganic fillers such heavy metal, nanoparticles, silica, and now more recently, carbon-based materials, like graphene and its derivatives.

Corrosion affects all industrial sectors where metals or metal alloys are used in their structures. In the automotive industry, the continuous search for lightweight parts has increased the demand for effective corrosion protection, in order to improve vehicle performance without compromising durability and safety. In this scenario, coatings are essential elements to preserve and protect vehicle parts from various environmental aggressions. Automotive coatings can be classified into primers, topcoats, clearcoats, and specialty coatings. Primers provide corrosion resistance and promote adhesion between the substrate and topcoat. Topcoats provide color, gloss, and durability to the coating system, while clearcoats enhance the appearance and durability of the finish. Specialty coatings provide additional properties, such as scratch resistance, chemical resistance, and UV protection.

Rubber is one of the most used materials currently selected to produce automotive parts, but, for specific applications, some improvement is required in its properties through the addition of some components to the rubber compound formulation. Because of that, mechanical, thermal, and chemical properties are enhanced in order to meet strict requirements of the vast range of application of the rubber compounds. In addition to improving material properties, the combination of different substances, also aims to improve processability and reduce the costs of the final product. Recently, the use of nanofillers has been very explored because of their distinctive properties and characteristics. Among the nanofillers under study, graphene is known for its high-barrier property, thermal and electrical conductivities, and good mechanical properties.

In recent years, the automotive industry has seen an exponential increase in the replacement of mechanical components with electronic-controlled components or systems. engine, transmission, brake, exhaust gas recirculation (EGR), lighting, driver-assist technologies, etc. are all monitored and/or controlled electronically. Connected vehicles are increasingly being used by Original Equipment Manufacturers (OEMs) to collect and transmit vehicle data in real-time via the use of various sensors, actuators, and communication technologies. Vehicle telematics devices can collect and transmit data about the vehicle location, speed, fuel efficiency, State Of Charge (SOC), auxiliary battery voltage, emissions, performance, and more. This data is sent over to the cloud via cellular networks, where it can be processed and analyzed to improve their products and services by automotive companies and/or fleet management.

Disc brake squeal is always a challenging multidisciplinary problem in vehicle noise, vibration, and harshness (NVH) that has been extensively researched. Theoretical analysis has been done to understand the mechanism of disc brake squeal due to small disturbances. Most studies have used linear modal approaches for the harmonic vibration of large models. However, time-domain approaches have been limited, as they are restricted to specific friction models and vibration patterns and are computationally expensive. This research aims to use a time-domain approach to improve the modeling of brake squeal, as it is a dynamic instability issue with a time-dependent friction force. The time-domain approach has been successfully demonstrated through examples and data.

Auto industry has faced constant challenges in the economic, technology and global trend in the recent years. This is changing the corporative mindset to find creative and innovative processes and methods to evolve the product development system to adjust and deliver competitive products that satisfy customers expectations. Integrating the work from different teams in an organization has been moving from simple roles and responsibilities definition with effective communication channels to a new vision where teamwork progresses in harmony and embraces change to satisfy customers as part of the process. The path to evolve work in engineering that relies on several computational tools continues. In this article, it is presented an integration of different tools to manage vehicle program changes using model-based systems engineering, the present work improves the reaction capabilities of the teams and enables to adjust to changes in the development of a vehicle.

With the proliferation of ADAS and autonomous systems, the quality and quantity of the data to be used by vehicles has become crucial. In-vehicle sensors are evolving, but their usability is limited to their field of view and detection distance. V2X communication systems solve these issues by creating a cooperative perception domain amongst road users and the infrastructure by communicating accurate, real-time information. In this paper, we propose a novel Consolidated Object Data Service (CODS) for multi-Radio Access Technology (RAT) V2X communication. This service collects information using BSM packets from the vehicular network and perception information from infrastructure-based sensors. The service then fuses the collected data, offering the communication participants with a consolidated, deduplicated, and accurate object database. Since fusing the objects is resource intensive, this service can save in-vehicle computation costs.

Fretting fatigue was observed in standard cylindrical fatigue samples at the regions in contact with the grips of the test frames during fatigue testing for AlSi10Mg aluminum alloy produced by laser powder bed fusion process (L-PBF). The failure of the fatigue sample grips occurs much earlier than the failure of the gauge section. This results in a damaged sample and the sample cannot be reused to continue the test. This type of failure is rarely seen in materials produced by traditional manufacturing processes. In this study, X-ray residual stress analysis was performed to understand the cause of failure for L-PBF AlSi10Mg with the as-built surface condition. The result indicates that the fretting fatigue failure was caused by the strong tensile residual stress in the as-built state combining with the fretting wear between the sample and the grip. A few potential solutions to avoid the fretting fatigue failure were investigated.

There are a multitude of dynamics faced by any industry. There is also a consistent search and development of technological platforms and services to address these changes. This necessitates a shared work philosophy which involves multiple stakeholders. Verification and validation are integral part of any development irrespective of product, process, or services. Also, every industry has a regulatory compliance to adhere too. But the extent of complexity and the level of dependencies or interactions between modules as well as stakeholders involved, creates slippage at some or other level. Nowadays the industries are also driven by reuse for cost effectiveness. Though it marks the significant improvement in the capability to compete, compatibility is a key measure to a successful product or service launch and sustainability.

In recent years there has been an increase in the development of vehicles that use alternative energy sources, more specifically electric vehicles, intending to establish the transition from combustion engines, bringing to the automotive chain a reduction in the consumption of fossil fuels. Electrified vehicles help to improve air quality by drastically reducing the emission of harmful gases and contributing to a considerable improvement in sound quality, due to the use of their silent electric motors. A material allied to these alternative technologies is graphene, few layers (usually up to 6) of Carbon atoms arranged in a hexagonal and crystalline form in a two-dimensional plane lattice. Its unique chemical structure allows it to share its exceptional properties with other materials, making it a strong candidate to meet the needs and improve products of the automotive sector.

Several factors stimulate the development of new materials in the industry. From specific physical-chemical characteristics to strategic market advantages, technology companies seek to diversify their raw materials. In the automotive sector, the current trend of electrification in vehicles and the increase of government and market demand for reducing the emission of greenhouse gases makes lighter materials more and more necessary. As electric vehicles use heavy batteries, the vehicle weight is directly related to its power demand and level of autonomy. The same applies to internal combustion vehicles where the vehicle weight directly impacts fuel consumption and emissions. In this context, there is a lot of research on special alloys and composites to replace traditional materials. Aluminum is a good alternative to steel due to its density which is almost five times smaller while that material still has good mechanical properties and has better impact absorption capability.

During the design conception of an automobile, typically low-fidelity physics-based simulations are coupled with engineering judgement to define key architectural components and subsystems which limits the capability to identify NVH issues arising from systems interaction. This translates to non-optimal designs because of unexplored design opportunities and therefore, lost business efficiencies. The sparse design information available during the design conception phase limits the development of representative higher fidelity physics-based simulations. To address that restriction on design optimization opportunities, this paper introduces an alternate approach to develop reduced order predictive models using regression techniques by harnessing historical measurement and simulation data. The concept is illustrated using two driveline NVH phenomenon: axle whine and take-off shudder.

The Composite Hybrid Automotive Suspension System Innovative Structures (CHASSIS) is a project that developed structural commercial vehicle suspension components in high volume utilising hybrid materials and joining techniques to offer a viable lightweight production alternative to steel. Three components were selected for the project:- Front Subframe Front Lower Control Arm (FLCA) Rear Deadbeam Axle

Laser welding of the magnesium-bearing AA5xxx aluminum alloys is often beset by keyhole instability, especially in the lap through joint configuration. This phenomenon is characterized by periodic collapse of the keyhole leaving large voids in the weld zone. In addition, the top surface can exhibit undercut and roughness. In full penetration welds, keyhole instability can also produce a spikey root and severe top surface concavity. These discontinuities could prevent a weld from achieving engineering specification compliance, pose a craftsmanship concern, or reduce the strength and fatigue performance of the weld. In the case of a full penetration weld, a spikey root could compromise part fit-up and corrosion protection, or damage adjacent sheet metal, wiring, interior components, or trim.

A novel laser-absorption gas sensing apparaOn-vehicle Testing at VERtus capable of measuring NO directly within vehicle exhaust was developed and tested. The sensor design was enabled by key advances in the construction of optical probes that are sufficiently compact for deployment in real-world exhaust systems and can survive the harsh, high-temperature, and strongly vibrating environment typical of exhaust streams. Prototype test campaigns were conducted at high-temperature flow facilities intended to simulate exhaust gas conditions and within the exhaust of vehicles mounted on a chassis dynamometer. Results from these tests demonstrated that the sensor prototype is fundamentally free of cross-interference with competing species in the exhaust stream, can achieve a 1 ppmv NO detection limit, and can be operated across the full range of thermodynamic conditions expected for typical vehicle exhausts.

Most of the applications of magnesium in lightweighting commercial cars and trucks are die castings rather than sheet metal, and automotive applications of magnesium sheet have typically been experimental or low-volume serial production. The overarching objective of this collaborative research project organized by the United States Automotive Materials Partnership (USAMP) was to develop new low-cost magnesium alloys, and demonstrate warm-stamping of magnesium sheet inner and outer door panels for a 2013 MY Ford Fusion at a fully accounted integrated component cost increase over conventional steel stamped components of no more than $2.50/lb. saved ($5.50/kg saved). The project demonstrated the computational design of new magnesium (Mg) alloys from atomistic levels, cast new experimental alloy ingots and explored thermomechanical rolling processes to produce thin Mg sheet of desired textures.

Noise and vibration evaluation of driveline clunk can be challenging as it is the result of driver input conditions and is transient in nature. As with many noise and vibration challenges, the use of computer-aided engineering (CAE) simulation is useful as it allows for detailed study of the phenomenon and prediction of potential improvements. A hybrid approach of physical test-based measurements and CAE analysis can be used to leverage the advantages of CAE in a comprehensive evaluation including the total vehicle noise, vibration, and harshness (NVH) performance. In this paper we present work performed to facilitate engineering evaluations of driveline clunk using both measured test and CAE simulation data. We explain how we used measured test data to inform the CAE analysis, how the simulation approached modelling of the transient clunk event, and how the measured data was used to provide contextual sound for realistic evaluation of the CAE output as heard by the passengers.