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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.

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 the present work, five surrogate components (n-Hexadecane, n-Tetradecane, Heptamethylnonane, Decalin, 1-Methylnaphthalene) are proposed to represent liquid phase of diesel fuel, and another different five surrogate components (n-Decane, n-Heptane, iso-Octane, MCH (methylcyclohexane), Toluene) are proposed to represent vapor phase of diesel fuel. For the vapor phase, a 5-component surrogate chemical kinetic mechanism has been developed and validated. In the mechanism, a recently updated H2/O2/CO/C1 detailed sub-mechanism is adopted for accurately predicting the laminar flame speeds over a wide range of operating conditions, also a recently updated C2-C3 detailed sub-mechanism is used due to its potential benefit on accurate flame propagation simulation. For each of the five diesel vapor surrogate components, a skeletal sub-mechanism, which determines the simulation of ignition delay times, is constructed for species C4-Cn.

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.

As the automotive industry strives for an increased fuel economy, lightweighting is a key factor and can be realized through composite materials. Composites have better strength-to-weight ratio as compared to metals. In this paper, static and fatigue analysis is performed on an oil pan made of polyamide-6,6 and 50% glass fiber (PA66-GF50). PA66 has a glass transition temperature of 170°C; therefore, it is suitable for automotive applications where the operating range is −40°C to 150°C. Long glass fiber (LGF) composite has an aspect ratio of 30-50 in the oil pan. Fibers break in the molding process but are still considerably longer than with conventionally compounded short glass fiber (SGF) composite, where the aspect ratio of fiber is between 10 and 20. However, the computer-aided engineering (CAE) procedure for life prediction of short glass fiber-reinforced (SGFR) plastic versus LGF-reinforced plastic is the same.

The work presented here is part of the research done in the field of voice biometrics. This paper helps to understand the state-of-the-art in speaker recognition technology potentially capable of solving challenges related to speaker identification (to identify a speaker among multiple speakers) and speaker verification/authentication (to recognize the current speaking person at a pre-defined access level and authenticate accordingly). The research was focused on performing an unbiased evaluation of two individual voice biometric services. The level of accuracy in identifying and authenticating individuals using these services provides an insight into the current state of technology and the state of what other dual authentication methods could be used to achieve a desired True Acceptance Rate (TAR) and False Acceptance Rates (FAR).

Model-guided development of drivetrain control and calibration is a key enabler of robust and efficient vehicle design process. A number of CAE tools are available today for modeling hydro-mechanical systems. Automatic transmission behaviors are well understood to effectively tune the model parameters for targeted applications. Drivetrain models provide physical insight for understanding the effects of component interactions on system behaviors. They are also widely used in HIL/SIL environments to debug control strategies. Nonetheless, it is still a challenge to predict shift quality, especially during a sequence of multiple events, with enough accuracy to support model-guided control design and calibration. The inclusion of hydraulic circuits in simulation models often results in challenges for numerical simulation.

Inside an automobile, hundreds of connectors and electrical terminals in various locations experience different corrosive environments. These connectors and electrical terminals need to be corrosion-proof and provide a good electrical contact for a vehicle’s lifetime. Saltwater and sulfuric acid are some of the main corrosion concerns for these electrical terminals. Currently, various thin metallic layers such as gold (Au), silver (Ag), or tin (Sn) are plated with a nickel (Ni) layer on copper alloy (Cu) terminals to ensure reliable electrical conduction during service. Graphene due to its excellent chemical stability can serve as a corrosion protective layer and prevent electrochemical oxidation of metallic terminals. In this work, effects of thin graphene layers grown by plasma-enhanced chemical vapor deposition (PECVD) on Au and Ag terminals and thin-film devices were investigated. Various mechanical, thermal/humidity, and electrical tests were performed.

A model-based urea-dosing controller has been developed for the selective catalytic reduction (SCR) units on a diesel engine exhaust aftertreatment system (EATS). The SCR units consist of an integrated SCR-coated filter and then followed by a flow-through SCR catalyst. The controller was developed based on an analysis of the data generated from a Millbrook London Transport Bus (MLTB) test cycle fed into a validated model of the SCR-filter and SCR units. The critical system parameters that showed strong correlation with outlet nitrogen oxides (NOx) and ammonia (NH3) emissions were first identified, and then the sensitivity of those parameters was analyzed. The most sensitive system parameters were configured as the controller gain parameters. A proportional controller based on the key parameters with optimized gains settings for the MLTB cycle delivered over a 10% reduction in cumulative NOx emission over the cycle compared to a fixed NH3/NOx ratio (ANR) controller.

As an alternative lightweight material, chopped carbon fiber reinforced Sheet Molding Compound (SMC) composites, formed by compression molding, provide a new material for automotive applications. In the present study, the monotonic and fatigue behavior of chopped carbon fiber reinforced SMC is investigated. Tensile tests were conducted on coupons with three different gauge length, and size effect was observed on the fracture strength. Since the fiber bundle is randomly distributed in the SMC plaques, a digital image correlation (DIC) system was used to obtain the local modulus distribution along the gauge section for each coupon. It was found that there is a relationship between the local modulus distribution and the final fracture location under tensile loading. The fatigue behavior under tension-tension (R=0.1) and tension-compression (R=-1) has also been evaluated.

Understanding and predicting in-cylinder flow structures that occur within compression-ignition engines is vital if further optimisation of combustion systems is to be achieved. To enable this prediction, fully validated computational models of the complex turbulent flow-fields generated during the intake and compression process are needed. However, generating, analysing and interpreting experimental data to achieve this validation remains a complex challenge due to the variability that occurs from cycle to cycle. The flow-velocity data gathered in this study, obtained from a single-cylinder CI engine with optical access using high-speed PIV, demonstrates that significantly different structures are generated over different cycles, resulting in the mean flow failing to adequately reflect the typical flow produced in-cylinder.

On current competitive scenario for road load transportation in Brazilian market, the operational costs should be reduced as much as possible. The suspension system commonly used on road commercial trucks is based on leaf spring use and Hotchkiss concept for axle locating devices. The use of leaf springs without bolt attachment eyelets are still common for rear suspension systems. When using the leaf spring with direct contact to the brackets, wear plates are placed between them to work as wear elements due to the friction between the parts. The friction will cause wear on the parts, and the wear plate is designed to suffer the damages of this friction instead of the leaf spring, being the cheapest element and can be easily replaced. When the system works on a severe contamination environment with high levels of grit and dirt, the degradation of the parts are accelerated.

Sunroof is placed in certain high-end vehicles to give user a better driving experience. All automakers are searching alternatives to reduce weight and cost in the vehicle, in which sunroofs are also impacted. Some alternatives are already applied, as a honeycomb paper used in some sunshades that presents benefits, as less weight and with a good cost reduction. Although, due the reduced weight for this part produced in this material, it shows more susceptibility to reproduce the vibration that vehicle propagates in movement, especially in bad condition roads. The sunroof assembly is dependent of the roof reinforcement and roof skin, but in this special case, the validation could be done in the components itself because the interaction of the sunshades is directly dependent of the other sunroof parts, as rails and front frame.

In this work we studied the effects of piston bowl design on combustion in a small-bore direct-injection diesel engine. Two bowl designs were compared: a conventional, omega-shaped bowl and a stepped-lip piston bowl. Experiments were carried out in the Sandia single-cylinder optical engine facility, with a medium-load, mild-boosted operating condition featuring a pilot+main injection strategy. CFD simulations were carried out with the FRESCO platform featuring full-geometric body-fitted mesh modeling of the engine and were validated against measured in-cylinder performance as well as soot natural luminosity images. Differences in combustion development were studied using the simulation results, and sensitivities to in-cylinder flow field (swirl ratio) and injection rate parameters were also analyzed.

The Single Sequential Turbocharger (SST) used in Ford’s 6.7L Scorpion Diesel is analyzed using Computational Fluid Dynamics (CFD) to draw conclusions about the compressor stability at low mass flows. The SST compressor concept consists of a double-sided wheel which flows in parallel fed by two separate inlets (front and rear), followed by a single vane-less diffuser, and a volute. CFD simulations for the full stage are performed at low mass flow rates Both, front and rear, sides have ported shroud casing-treatment (CT) in the inlet region. An objective of the analysis is to determine which side of the SST unit compressor (front or rear on the double-sided wheel) suffers flow break down first as the mass flow is reduced, and its impact on the overall stability of the SST compressor. Another objective is to better understand the interactions between the compressor inlet flow and the flow through the casing-treatment.

Electrically assisted turbochargers are a promising technology for improving boost response of turbocharged engines. These systems include a turbocharger shaft mounted electric motor/generator. In the assist mode, electrical energy is applied to the turbocharger shaft via the motor function, while in the regenerative mode energy can be extracted from the shaft via the generator function, hence these systems are also referred to as regenerative electrically assisted turbochargers (REAT). REAT allows simultaneous improvement of boost response and fuel economy of boosted engines. This is achieved by optimally scheduling the electrical assist and regeneration actions. REAT also allows the exhaust turbine to operate within a narrow range of optimal vane positions relative to the unassisted variable geometry turbocharger (VGT). The ability to operate within a narrow range of VGT vane positions allows an opportunity for a more optimal turbine design for a REAT system.

Engine downsizing is a promising trend to decarbonise vehicles but it also poses a challenge on vehicle driveability. Electric turbochargers can solve the dilemma between engine downsizing and vehicle driveability. Using the electric turbocharger, the transient response at low engine speeds can be recovered by air boosting assistance. Meanwhile, the introduction of electric machine makes the engine control more complicated. One emerging issue is to harness the augmented engine air system in a systematical way. Therefore, the boosting requirement can be achieved fast without violating exhaust emission standards. Another raised issue is to design an real time energy management strategy. This is of critical to minimise the required battery capacity. Moreover, using the on-board battery in a high efficient way is essential to avoid over-frequent switching of the electric machine. This requests the electric machine to work as a generator to recharge the battery.

Engine oil plays an important role in improving fuel economy of vehicles by reducing frictional losses in an engine. Our previous investigation explored the friction reduction potential of next generation engine oils by looking into the effects of friction modifiers and dispersant Inhibitor packages when engine oil was fresh. However, engine oil starts aging the moment engine start firing because of high temperature and interactions with combustion gases. Therefore, it is more relevant to investigate friction characteristics of aged oils. In this investigation, oils were aged for 5000 miles in taxi cab application.

Corrosion is a known phenomenon that the automotive industry needs to pay attention, once that several issues faced in the field had it as root cause. Indisputably is important spend resources in usage of proper materials and process based on chemical properties, minimum thickness, adhesion conditions, wear resistance, finish applicators, etc. to cover the parts in order to ensure robust protection against this phenomena; however, the key point is to optimize these resources once that the customer will buy/use the vehicle (not the part singly); so if develop a proper design in system level providing proper protection of the parts, despite of the part does not have the most efficient protection level, the customers will have a satisfactory experience during vehicle usage.