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Crashes involving Cummins powered heavy vehicles can damage the electronic control module (ECM) containing heavy vehicle event data recorder (HVEDR) records. When ECMs are broken and data cannot be extracted using vehicle diagnostics tools, more invasive and low-level techniques are needed to forensically preserve and decode HVEDR data. A technique for extracting non-volatile memory contents using non-destructive board level techniques through the available in-circuit debugging port is presented. Additional chip level data extraction techniques can also provide access to the HVEDR data. Once the data is obtained and preserved in a forensically sound manner, the binary record is decoded to reveal typical HVDER data like engine speed, vehicle speed, accelerator pedal position, and other status data. The memory contents from the ECM can be written to a surrogate and decoded with traditional maintenance and diagnostic software.

The research described examines the relationship between damage/repair scenarios and the resulting effect on the coupled response of the structure. The monocoque is simplified as a box beam and damage is simulated by introducing a hole in one side of the tube. Repair is simulated by adding plies to an undamaged area of the beam side. Composite beam samples were manufactured and tested using a 3-axis coordinate measurement machine (CMM), to experimentally verify the computer numerical predictions of the deformed shape. The beams were loaded with a combined torsion-bending load using an eccentric tip load and rigidly fixing the opposite end. Structural coupling was observed by computing the distortion center of the beam profile at cross-sections along its length and comparing the results to the undamaged/unrepaired beam. The experimental results correlate well with the finite element simulations and generally follow the predictions of the analytical model.

Internal combustion engine poppet valves operate in extreme conditions. These extreme conditions are a result of the high temperatures in the combustion chamber. Especially in Motorsport applications, the high temperatures have led to the development of exotic metallic alloys that can operate in this environment. One key problem in developing materials for poppet valves is that it is necessary to know the temperature at which they operate. This is increasingly important when developing valves from alternative materials such as fiber reinforced composites. Composite engine valves have the potential to produce substantial increases in engine performance, through substantial weight reductions, if they can be designed to withstand the environment. Research to-date has demonstrated the functionality of fiber reinforced composite intake valves that are significantly lighter than metallic valves; however, composite valve surface temperatures seem higher than expected.

Fiber reinforced, shape memory, polymer matrix, composites have recently been demonstrated in a variety of applications. Once cured, these composites, based on thermoset shape memory resins, have the ability to be semi-permanently deformed from the cured shape at elevated temperatures and then subsequently returned to the original shape. However, the vast majority of the applications demonstrated have made use of very thin composite laminates. The current research considers composite sandwich panel structures formed from shape memory composite facesheets and a rigid foam core created from shape memory resin. The goal is to investigate the potential deformability in these much more rigid geometries to assess the potential for use in conformable, structural applications.

Predictive capabilities and understanding of how energy absorbing composite structures can be constructed, without additional size or weight, are necessary in order to ensure the deceleration of the driver is kept below human threshold levels. Often, the deceleration rate is modified by changes in the core or crushable material of the composite structure. In the current research, carbon fiber energy attenuators were designed, constructed, and tested to demonstrate the ability to tailor the energy absorbing profile through changes of the fiber orientation and ply stacking sequence. Reinforcing wraps of uni-directional carbon fiber were used to modify a baseline ply sequence and improved response was recorded in each case.

A study is presented in which light-weight composite materials are used for an engine intake valve. This paper is an interim progress report and documents the successful demonstration of a net-shape, resin transfer molded intake valve in a running engine. A short review of a previous dynamic model is presented showing the advantages in engine performance by using the composite valves. It is shown that the use of reduced mass composite valves allows for increased engine speed and/or more aggressive cam profiles without sacrificing valve strength or stiffness while at the same time maintaining reliable operation. The use of composite materials allows for a significant weight reduction compared to more conventional materials such as steel and titanium. A brief review of the use of composite materials is presented. The development and design process for carbon fiber reinforced valves is discussed.

A current general need within Six Sigma methodologies is to utilize statistical methods including experimental design in the confirmation of new processes and their parameters. This is typically done in the improve step of the DMAIC process. This need is even more evident in microjoining (small scale resistance welding) due to the number and complexity of the process variables. This paper outlines the improve step of a Six Sigma project in which statistical methods are applied to a microjoining process. These statistical methods include linear experimental design, regression analysis with linear transformation and mathematical modeling. The paper documents the methodology used to establish process parameters in microjoining of an electrical lead frame design.

Quality issues in magnet wire stripping and soldering have led to continuous improvement efforts in ignition coil manufacturing using Six Sigma methodologies. This effort has resulted in the investigation of an alternative product and process design, microjoining. This paper describes the continuation of development occurring during the improvement phase of a Six Sigma project. The confirmation of the results is accomplished through the use of experimental design, response surface methodologies, mathematical modeling and optimization of the process. Nonlinear design of experiments have been used to confirm a breakthrough microjoining process developed that is an alternative to soldering. The statistical methods used to develop the process build on the current documented research efforts.