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Standard

Performance Specification for Welded Wire-to-Wire Splices

2018-06-14
CURRENT
USCAR45
SAE/USCAR-45 defines test methods and performance requirements for ultrasonically-welded wire-to-wire splices for automotive applications. Face-to-face, butt splice, and center strip configurations per Figure 1 can be tested. The tests defined in this specification subject samples on test to stresses that simulate a lifetime of exposure for a road vehicle. Stresses called out in this specification include thermal shock, temperature/humidity cycling and mechanical stress from different directions.
Standard

Performance Specification for Ultrasonically welded wire terminations

2016-04-05
CURRENT
USCAR38-1
This specification defines test methods and performance criteria for evaluating ultrasonically welded wire-to-terminal metallurgical bonds. The examples used are specific to the linear weld type of process equipment. USCAR-38 is not applicable for “Splice Welding”. The specification is applicable to wire-on-pad configurations with a typical weld shown in Figure 1. This test specification subjects parts under test to environmental exposures to simulate a lifetime of field exposure for a road vehicle. Exposures called-out in this specification include Thermal Shock, Temperature Humidity Cycling and mechanical abuse. This test specification is intended to evaluate the strength and performance of the interface between wires to an electrical terminal. Validation of the performance of the Terminal is a separate task and can be accomplished using a component validation test such as SAE/USCAR-2, which evaluates whether the entire connection system is acceptable.
Standard

Shipping Caps, Torque Caps, and Body Plugs Ergonomic Design Criteria

2015-03-30
CURRENT
USCAR43
This document describes the design and assembly force guidelines for conventional shipping caps, torque caps, and body plugs. All possible design and applications could not be anticipated in creating these guidelines. Where there are questions of adherence to to this document, such as use of an “off-the-shelf” design, always consult the responsible Ergonomics Department.
Standard

Ergonomic Guidelines for Carts and Dollies

2015-03-13
CURRENT
USCAR41
This document describes the assessment methods and physical requirements associated with the manual handling of carts and dollies, specific to material handling systems. All possible designs and applications could not be anticipated in creating these guidelines. Where there are questions of adherence to this document, such as use of an “off-the shelf” design, always consult the responsible Ergonomics Department. Force guidelines were primarily developed referencing the push/pull psychophysical Snook data contained in A Guide to Manual Materials Handling (second edition) by Mital, Nicholson and Ayoub (NY: Taylor & Francis, 1997). The force guidelines accommodate 75% of female capabilities and 99% of male capabilities. Factors that were included in the established guideline include: push / pull distances, vertical hand height, horizontal hand height, frequency and wheel / castor alignment and load rating. These factors were used to develop a conservative force guideline.
Standard

Ergonomic Guidelines for Small Lot Delivery Operations

2015-03-10
CURRENT
USCAR42
This document describes the design, assessment methods and physical requirements associated with material handling systems. This would include, but not limited to manual dollies, small lot systems and kitting. All possible designs and applications could not be anticipated in creating these guidelines. Where there are questions of adherence to this document, such as use of an “off-the shelf” design, always consult the responsible Ergonomics Department.
Standard

Standard for Cigar Lighters & Power Outlets

2014-03-31
CURRENT
USCAR4-1
This standard is intended to cover cigar or cigarette lighters as well as power outlets based on the form and dimensions of the cigar lighter. This standard is a full performance specification, it includes dimensional and operational parameters as well as performance characteristics which must be met when submitting a cigar lighter assembly or power outlet assembly for production approval. This standard constitutes an acceptance specification for a surface mounted, front-loaded cigar lighter or power outlet.
Standard

Dimensional and Performance Specification for After-Market Gasoline Engine Oil Filters

2013-01-30
CURRENT
USCAR36
This specification defines the dimensional and performance requirements for aftermarket spin-on oil filters intended for use on gasoline engines. Filters meeting this specification may also be suitable for use on some diesel applications. Filters meeting these dimensional limits are intended to meet the oil filter fit and package requirements for engine and vehicle designs. Filters meeting the performance requirements are intended to maintain sufficient durability to support many of the OEM's recommended oil change intervals. Some OEM engines may require special filters for which this specification would not support.
Standard

DEEMBRITTLEMENT VERIFICATION TEST

2012-07-30
CURRENT
USCAR7-1
This standard outlines test methods and practices which can detect embrittlement of steel parts. It is a process control or referee verification test. The risk of embrittlement of steel is minimized by using best practices in the finishing/coating process. One such practice is described in SAE/USCAR-5, Avoidance of Hydrogen Embrittlement of Steel.
Standard

Performance Specification for Ultrasonically Welded Wire/Cable Termination

2009-12-18
HISTORICAL
USCAR38
IMPORTANT NOTICE: In any intended vehicle application, if the products covered by this specification are, or may be, subjected to conditions beyond those described in this document, they must pass special tests simulating the actual conditions to be encountered before they can be considered acceptable for actual vehicle application. Products certified by their supplier as having passed specific applicable portions of this specification are not to be used in applications where conditions may exceed those for which the product has been satisfactorily tested. The Authorized Person is the final authority as to what tests are to be performed on his or her parts and for what purpose these tests are required. He or she is also the final authority for resolving any questions related to testing to this specification and to authorizing any deviations to the equipment or procedures contained in this specification.
Standard

AVOIDANCE OF HYDROGEN EMBRITTLEMENT OF STEEL

2008-06-01
HISTORICAL
USCAR5-4
This standard outlines the conditions that enhance the risk of hydrogen embrittlement of steel and define the relief procedures required to minimize the risk of hydrogen embrittlement. It is intended to control the process.
Standard

TORQUE-TENSION TESTING AND EVALUATION OF FASTENER FINISHES

2007-03-01
CURRENT
USCAR11-1
This standard provides a test method for determining the torque-tension relationship of a fastener finish as applied to a surrogate screw for the purpose of measuring the frictional characteristic of the fastener finish. The results obtained by this test shall be used as a process control attribute of the fastener finish and shall not be utilized for specific applications.
Standard

STANDARD FOR D.C. BRUSH MOTOR – HVAC BLOWERS

1999-02-01
CURRENT
USCAR6
This standard sets forth the performance and durability requirements for 12-volt, D.C. brush-type electric motors used for automobile Heating, Ventilation, and Air Conditioning (HVAC) blowers and outlines Production Validation and Continuing Conformance testing.
Standard

STANDARD FOR CIGAR LIGHTERS & POWER OUTLETS

1997-11-01
HISTORICAL
USCAR4
This standard is intended to cover cigar or cigarette lighters as well as power outlets based on the form and dimensions of the cigar lighter. This standard is a full performance specification, it includes dimensional and operational parameters as well as performance characteristics which must be met when submitting a cigar lighter assembly or power outlet assembly for production approval. This standard constitutes an acceptance specification for a surface mounted, front-loaded cigar lighter or power outlet.
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