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It is common to see application of simulations to Support product development, being parts, sub-system or complete product, like a passenger vehicle. Another possible application of the simulation is to simulate assembly of parts and sub-systems. This paper captures one example of this application, where the headlamp aim adjustment done during the assembly line, is simulated to provide design changes to avoid issues during the normal production.

This work consists of evaluating the influence of heat treatment on sintered valve seat insert (VSI) obtained with two different high-speed steels powders and one tool steel: AISI M3:2, AISI M2 and AISI D2, respectively. The high-speed / tool steel powders were mixed with iron powders and additives such as manganese sulphide, zinc stearate, graphite and niobium carbide. All the high-speed / tool steel powders had its particle size distribution and morphology analyzed. The heat treatment of the VSI consisted of air quenching followed by double tempering it in seven different and equidistant temperatures, ranging from 100 °C until 700 °C. A data acquisition system with a thermocouple type k attached to the samples was used to determine the air-quenching cooling rate. The mechanical and physical properties measurements were carried out, i.e., apparent density, apparent hardness and crush radial strength.

This paper reports the experimental efforts in recording the 2-dimensional temperature distribution on autogenous thin plates of UNS S32304 steel during welding. The butt-welded autogenous joints were experimentally performed by the GTAW (Gas Tungsten Arc Welding) process with either argon or argon-2%nitrogen atmospheres. The temperatures cycles were recorded by means of thermocouples embedded by spot welding on the plate's surfaces and connected to a multi-channel data acquisition system. The laser flash method (LFM) was also used for the determination thermal diffusivity of the material in the thickness direction. The temperature curves suggest a relationship between the microstructures in the solidified and the heat affected zone with the diffusivity variation. This is a region where there had been a major incidence of heat. The obtained results validate the reliability of the experimental used apparatus.

This paper presents a technological comparison of weldability and mechanical properties between a dual phase steel (DP) and an advanced high strength low alloy steel (AHSLA) used for automotive structural parts in order to demonstrate some unclear characteristics of each. Samples were spot welded and had their hardness and microstructure analyzed, also a shear test was applied on the weld button area. The edge stretchability was analyzed using hole expansion tests and tensile tests to determine the tensile and yield strength, anisotropic coefficients and total elongation. Data were used to estimate crash energy absorption. The results showed an AHSLA steel with higher than typical ductility. Finally, while DP showed improved stretchability, it was also concluded that such AHSLA could perform better bendability, drawability, flangeability and weldability.

Fiberglass laminated parts are used in automotive industry, especially for limited quantities of parts production. They are useful on prototypes and special vehicles, among other things. If the parts are not laminated with required quality, the result can jeopardize the vehicle parts application. This paper shows a simple manner of vacuum bagging process application for fiberglass and carbon fiber parts lamination with dimensional and surface quality required. It also shows the mould fabrication process and its importance to the laminated parts quality.

The compromise for a race car can be completely different from a road car and these differences become even greater when this car is a light pickup. The target for a race car is to cover a determined distance in the shortest time and when this distance is a thousand miles, lap time is not the only objective. The compromise must include fuel consumption, tire wear, brake wear and even driver fatigue. This paper describes the full preparation, from the production vehicle to the final race car, which has competed successfully in the Brazilian 2004 Mil Milhas.

The suspension for a road car focuses in a good compromise between Ride & Handling. When this car is a light pickup, there is also an important compromise between driver and full load condition. For a race car, the suspension system must have a different compromise, were Ride is not considered, but it must be able to keep the tire in contact with the ground, transforming engine power into acceleration, brake power into deceleration and steering inputs in correct corner apex. This paper describes the suspension modification in a production Chevrolet Montana and the methodology used to specify springs, anti roll bars and dampers, which has competed successfully in the 32a Mil Milhas de Interlagos.