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The Selective Laser Melting (SLM) process is employed in high-precision layer-by-layer Additive Manufacturing (AM) on powder bed and aims to fabricate high-quality structural components. To gain a comprehensive understanding of the process and its optimization, both modeling and simulation in conjunction with extensive experimental studies along with laser calibration studies have been attempted. Multiscale and multi-physics-based simulations have the potential to bring out a new level of insight into the complex interaction of laser melting, solidification, and defect formation in the SLM parts. SLM process encompasses various physical phenomena during the formation of metal parts, starting with laser beam incidence and heat generation, heat transfer, melt/fluid flow, phase transition, and microstructure solidification. To effectively model this Multiphysics problem, it is imperative to consider different scales and compatible boundary conditions in the simulations.

Bio-composites have gained significant attention within the aerospace industry due to their potential as a sustainable solution that addresses the demand for lightweight materials with reduced environmental impact. These materials blend natural fibers sourced from renewable origins, such as plant-based fibers, with polymer matrices to fabricate composite materials that exhibit desirable mechanical properties and environmental friendliness. The aerospace sector's growing interest in bio-composites originates from those composites’ capacity to mitigate the industry's carbon footprint and decrease dependence on finite resources. This study aims to investigate the suitability of utilizing plant derived flax fabric/PLA (polylactic acid) matrix-based bio-composites in aerospace applications, as well as the recyclability potential of these composites in the circular manufacturing economy.

Selective Laser Melting (SLM) has gained widespread usage in aviation, aerospace, and die manufacturing due to its exceptional capacity for producing intricate metal components of highly complex geometries. Nevertheless, the instability inherent in the SLM process frequently results in irregularities in the quality of the fabricated components. As a result, this hinders the continuous progress and wider acceptance of SLM technology. Addressing these challenges, in-process quality control strategies during SLM operations have emerged as effective remedies for mitigating the quality inconsistencies found in the final components. This study focuses on utilizing optical emission spectroscopy and IR thermography to continuously monitor and analyze the SLM process within the powder bed, with the aim of strengthening process control and minimizing defects.

Enhanced protection against high speed crashes requires more aggressive passive safety countermeasures as compared to what are provided in vehicle structures today. Apart from such collision-related scenarios, high energy explosions, accidentally caused or otherwise, require superior energy-absorbing capability of vehicle body subsystems. A case in point is a passenger vehicle subjected to an underbody blast emanating shock wave energy of military standards. In the current study, assessment of the behavior of a “hollow” countermeasure in the form of a depressed steel false floor panel attached with spot-welds along flanges to a typical predominantly flat floor panel of a car is initially carried out with an explicit LS-DYNA solver. This is followed up with the evaluation of PU (polyurethane) foam-filled and liquid-filled false floor countermeasures. In all cases, a charge is detonated under the false floor subjecting it to a high-energy shock pressure loading.

Adhesive bonding provides a versatile strategy for joining metallic as well as non-metallic substrates, and also offers the functionality for joining dissimilar materials. In the design of unibody vehicles for NVH (Noise, Vibration and Harshness) performance, adhesive bonding of sheet metal parts along flanges can provide enhanced stiffening of body-in-white (BIW) leading to superior vibration resistance at low frequencies and improved acoustics due to sealing of openings between flanges. However, due to the brittle nature of adhesives, they remain susceptible to failure under impact loading conditions. The viability of structural adhesives as a sole or predominant mode of joining stamped sheet metal panels into closed hollow sections such as hat-sections thus remains suspect and requires further investigation.

Designing a vehicle for superior crash safety performance in consumer rating tests such as US-NCAP is a compelling target in the design of passenger vehicles. In today’s context, there is also a high emphasis on making a vehicle as lightweight as possible which calls for an efficient design. In modern vehicle design, these objectives can only be achieved through Computer-Aided Engineering (CAE) for which a detailed CAD (Computer-Aided Design) model of a vehicle is a pre-requisite. In the absence of the latter (i.e. a matured CAD model) at the initial and perhaps the most crucial phase of vehicle body design, a rational approach to design would be to resort to a knowledge-based methodology which can enable crash safety assessment of an assumed design using artificial intelligence techniques such as neural networks.

Natural fiber-reinforced composites are currently gaining increasing attention as potential substitutes to pervasive synthetic fiber-reinforced composites, particularly glass fiber-reinforced plastics (GFRP). The advantages of the former category of composites include (a) being conducive to occupational health and safety during fabrication of parts as well as handling as compared to GFRP, (b) economy especially when compared to carbon fiber-reinforced composites (CFRC), (c) biodegradability of fibers, and (d) aesthetic appeal. Jute fibers are especially relevant in this context as jute fabric has a consistent supply base with reliable mechanical properties. Recent studies have shown that components such as tubes and plates made of jute-polyester (JP) composites can have competitive performance under impact loading when compared with similar GFRP-based structures.

Recent experimental studies on the behavior of adhesively-bonded steel double-hat section components under axial impact loading have produced encouraging results in terms of load-displacement response and energy absorption when compared to traditional spot-welded hat- sections. However, it appears that extremely limited study has been carried out on the behavior of such components under transverse impact loading keeping in mind applications such as automotive body structures subject to lateral/side impact. In the present work, lateral impact studies have been carried out in a drop-weight test set-up on adhesively-bonded steel double-hat section components and the performance of such components has been compared against their conventional spot-welded and hybrid counterparts. It is clarified that hybrid components in the present context refer to adhesively-bonded hat-sections with a few spot welds only aimed at preventing catastrophic flange separations.

There has been a keen interest in recent times on implementation of lightweight materials in vehicles to bring down the unladen weight of a vehicle for enhancing fuel efficiency. Fiber-reinforced composites comprise a class of such materials. As sustainability is also a preoccupation of current product development engineers including vehicle designers, bio-composites based on natural fibers are receiving a special attention. Keeping these motivations of lower effective density, environment friendliness and occupational safety in mind, woven jute fabric based composites have been recently studied as potential alternatives to glass fiber composites for structural applications in automobiles. In the past, mechanical characterization of jute-polyester composites were restricted to obtaining their stress-strain behaviors under quasi-static conditions.

Adhesively bonded steel hat section components have been experimentally studied in the past as a potential alternative to traditional hat section components with spot-welded flanges. One of the concerns with such components has been their performance under axial impact loading as adhesive is far more brittle as compared to a spot weld. However, recent drop-weight impact tests have shown that the energy absorption capabilities of adhesively bonded steel hat sections are competitive with respect to geometrically similar spot-welded specimens. Although flange separation may take place in the case of a specimen employing a rubber toughened epoxy adhesive, the failure would have taken place post progressive buckling and absorption of impact energy.

The present work is concerned with the objective of design optimization of an automotive front end structure meeting both occupant and pedestrian safety requirements. The main goal adopted here is minimizing the mass of the front end structure meeting the safety requirements without sacrificing the performance targets. The front end structure should be sufficiently stiff to protect the occupant by absorbing the impact energy generated during a high speed frontal collision and at the same time it should not induce unduly high impact loads during a low speed pedestrian collision. These two requirements are potentially in conflict with each other; however, there may exist an optimum design solution, in terms of mass of front end structure, that meets both the requirements.

Periprosthetic fractures refer to the fractures that occur in the vicinity of the implants of joint replacement arthroplasty. Most of the fractures during an automotive frontal collision involve the long bones of the lower limbs (femur and tibia). Since the prevalence of persons living with lower limb joint prostheses is increasing, periprosthetic fractures that occur during vehicular accidents are likely to become a considerable burden on health care systems. It is estimated that approximately 4.0 million adults in the U.S. currently live with Total Knee Replacement (TKR) implants. Therefore, it is essential to study the injury patterns that occur in the long bone of a lower limb containing a total knee prosthesis. The aim of the present study is to develop an advanced finite element model that simulates the possible fracture patterns that are likely during vehicular accidents involving occupants who have knee joint prostheses in situ.

An attractive strategy for joining metallic as well as non-metallic substrates through adhesive bonding. This technique of joining also offers the functionality for joining dissimilar materials. However, doubts are often expressed on the ability of such joints to perform on par with other mechanical fastening methodologies such as welding, riveting, etc. In the current study, adhesively-bonded single lap shear (SLS), double lap shear (DLS) and T-peel joints are studied initially under quasi-static loading using substrates made of a grade of mild steel and an epoxy-based adhesive of a renowned make (Huntsman). Additionally, single lap shear joints comprised of a single spot weld are tested under quasi-static loading. The shear strengths of adhesively-bonded SLS joints and spot-welded SLS joints are found to be similar. An important consideration in the deployment of adhesively bonded joints in automotive body structures would be the performance of such joints under impact loading.

Rapid progress in the interdisciplinary field of automotive engineering and the pressing need for an environmental friendly alternative to metal and synthetic fiber-reinforced composites for vehicle structure have triggered recent research in the field of natural fiber-based composites. Their potential advantages are attributed to their light weight, low cost and biodegradability. However, their usage in present day automotive systems is restricted due a lower magnitude range of mechanical properties and limited study in this area. In contrast to mechanical joints, the adhesively bonded joints aid in reducing stress concentration, joining of dissimilar materials, corrosion prevention, weight reduction and a smoother finish. Thus, in the present study, failure load, and mean shear stress of single lap shear and double lap shear joints as a function of joint overlap length, are evaluated using a two part epoxy adhesive made by Huntsman.

Rigid polyurethane (PU) foam finds wide applications as a lightweight material in impact safety design such as improving occupant safety in vehicle crashes. The two principal reacting compounds for formulating such foam are variants of polyol and isocyanate. In the present study, an alternative mechanical engineering-based approach for determining, with confidence, the desirable ratio of reacting compounds for formulation of a rigid/crushable PU foam for mechanical applications is demonstrated. According to the present approach, PU foam samples are prepared by varying the mixing ratio over a wide range. The desirable mixing ratio is shown to be the one that optimizes key mechanical properties under compression such as total absorbed energy, specific absorbed energy and energy absorption efficiency.

Idealized mathematical models, also known as lumped parameter models (LPMs), are widely used in analyzing vehicles for ride comfort and driving attributes. However, the limitations of some of these LPMs are sometimes not apparent and a rigorous comparative study of common LPMs is necessary in ascertaining their suitability for various dynamic situations. In the present study, the mathematical descriptions of three common LPMs, viz. quarter, half and full car models, are systematically presented and solved for the appropriate response parameters such as body acceleration, body displacement, and, pitch and roll angles using representative passive suspension system properties. By carrying out a comparison of the three stated LPMs for hump-type road profiles, important quantitative insights, not previously reported in the literature, are generated into their behaviors so that their applications can be judicious and efficient.

The usage of lightweight materials such as plastics and their derivatives continues to increase in automobiles driven by the urgency for weight reduction. For structural performance, body components such as A-pillar or B-pillar trim, instrument panel, etc. have to meet various requirements including resistance to penetration and energy absorption capability under impact indentation. A range of plain and reinforced thermoplastics and thermosetting plastics has been considered in the present study in the form of plates which are subject to low velocity perforation in a drop-weight impact testing set-up with a rigid cylindrical indenter fitted to a tup. The tested plates are made of polypropylene (PP), nanoclay-reinforced PP of various percentages of nanoclay content, wood-PP composites of different volume fractions of wood fiber, a jute-polyester composite, and a hybrid jute-polyester reinforced with steel.

Load cells and accelerometers are commonly used sensors for capturing impact responses. The basic objective of the present study is to assess the accuracy of responses recorded by the said transducers when these are mounted on a moving impactor. In the present work, evaluation of the responses obtained from a drop-weight impact testing set-up for an axially loaded specimen has been carried out with the aid of an equivalent lumped parameter model (LPM) of the set-up. In this idealization, a test component such as a steel double hat section subjected to axial impact load is represented with a nonlinear spring. Both the load cell and the accelerometer are represented with linear springs, while the impactor comprising a hammer and a main body with the load cell in between are modelled as rigid masses. An experimentally obtained force-displacement response is assumed to be a true behavior of a specimen.

Natural fiber-based composites such as jute-polyester composites have the potential to be more cost-effective and environment-friendly substitutes for glass fiber-reinforced composites which are commonly found in many applications. In an earlier study (Mache and Deb [1]), jute-polyester composite tubes of circular and square cross-sections were shown to perform competitively under axial impact loading conditions when compared to similar components made of bidirectional E-glass fiber mats and thermo-setting polyester resin. For jute-reinforced plastic panels to be feasible solutions for automotive interior trim panels, laminates made of such materials should have adequate perforation resistance. In the current study, a systematic characterization of jute-polyester and glass-polyester composite laminates made by compression molding is at first carried out under quasi-static tensile, compressive and flexural loading conditions.

Growing consumer expectations continue to fuel further advancements in vehicle ride comfort analysis including development of a comprehensive tool capable of aiding the understanding of ride comfort. To date, most of the work on biodynamic responses of human body in the context of ride comfort mainly concentrates on driver or a designated occupant and therefore leaves the scope for further work on ride comfort analysis covering a larger number of occupants with detailed modeling of their body segments. In the present study, governing equations of a 13-DOF (degrees-of-freedom) lumped parameter model (LPM) of a full car with seats (7-DOF without seats) and a 7-DOF occupant model, a linear version of an earlier non-linear occupant model, are presented. One or more occupant models can be coupled with the vehicle model resulting into a maximum of 48-DOF LPM for a car with five occupants.