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A new variable compression turbo (VC-Turbo) engine, which has a multi-link system for controlling the compression ratio from 8:1 to 14:1, requires high axial force for fastening the multi-links because of high input loads and the downsizing requirement. Therefore, it was necessary to develop a 1.6-GPa tensile strength bolt with plastic region tightening. One of the biggest technical concerns is delayed fracture. In this study, quenched and tempered alloy steels were chosen for the 1.6-GPa tensile strength bolt.

The purpose of this work was to gain a fundamental understanding of which fuel property parameters are responsible for particulate emission characteristics, associated with key intermediate behavior in the engine cylinder such as the fuel film and insufficient mixing. Accordingly, engine tests were carried out using various fuels having different volatility and chemical compositions under different coolant temperature conditions. In addition, a fundamental spray and film visualization analysis was also conducted using a constant volume vessel, assuming the engine test conditions. As for the physical effects, the test results showed that a low volatility fuel displayed high particulate number (PN) emissions when the injection timing was advanced. The fundamental test clearly showed that the amount of fuel film on the impingement plate increased under such operating conditions with a low volatility fuel.

This paper presents the technologies incorporated in an electric vehicle (EV)/hybrid electric vehicle (HEV) inverter built with power semiconductors of silicon carbide (SiC) metal-oxide-semiconductor field-effect transistors (MOSFETs) instead of conventional silicon (Si) insulated gate bipolar transistors (IGBTs). A SiC inverter prototype of 2.9 L in size for driving an 80-kW motor was fabricated and evaluated on a motor test bench. The SiC inverter prototype attained average efficiency of 98.5% in the Worldwide harmonized Light-duty Test Cycle (WLTC) driving mode. The two main technologies achieved with this SiC inverter prototype are described. The first one is a new direct-cooled power module with a thick copper (Cu) heat spreader located under the semiconductors that improves thermal resistance by 34% compared with a conventional direct-cooled power module.

A suitable GF-5 engine oil formulation is investigated to improve the fuel economy of gasoline engines with hydrogen-free DLC-coated valve lifters. Molybdenum dithocarbamate (MoDTC) is shown to be a suitable friction modifier for low viscosity grade engine oils like 0W-20. A suitable Ca salicylate detergent is also determined from several types examined for maximizing the friction reduction effects of MoDTC. The most suitable Ca salicylate has a chemical structure capable of forming a borophosphate glass film on metal surfaces, which is known to improve the effects of MoDTC. A high viscosity index Group III base oil (VI>140) is also effective in improving fuel efficiency. It is further clarified that the structural design of the polymethacrylate viscosity modifier is another important factor in reducing engine friction.

Use of high strength steel (HSS) could be an important consideration in achieving competitive weight and safety performance of the body-in-white (BIW). This study covers key technical issues in the application development. Many aspects were studied such as formability, weldability and impact strength for application of this grade to the BIW. One of the key issues is spot weldability, especially in the assembly of heavy gauge materials for structural parts. The spot weld strength appears not to satisfy the target for some HSS applications, when hardness of the nugget is high. The relation between weld strength and the chemical composition of steel sheets was studied, because hardness can be controlled by chemical composition and welding conditions. It was found that using lower carbon content or carbon equivalent compared to conventional grades could improve weld strength.

A transient knock prediction technique has been developed by coupling a zero-dimensional knocking simulation with chemical kinetics and a one-dimensional gas exchange engine model to study the occurrence of transient knock in SI engines. A mixed chemical reaction mechanism of the primary reference fuels was implemented in the two-zone combustion chamber model as the auto-ignition model of the end-gas. An empirical correlation between end-gas auto-ignition and knock intensity obtained through intensive analysis of experimental data has been applied to the knocking simulation with the aim of obtaining better prediction accuracy. The results of calculations made under various engine operating parameters show good agreement with experimental data for trace knock sensitivity to spark advance.

It was found that pitting resistance of gears is strongly influenced by resistance to temper softening of carburized steel. The investigation about the influence of chemical compositions on hardness after tempering revealed that silicon, chromium and molybdenum are effective elements to improve resistance to temper softening and pitting resistance. Considering the production of gears, molybdenum is unfavorable because it increases hardness of normalized or annealed condition. Developed new steel contains about 0.5 mass% of silicon and 2.7 mass% chromium. The new steel has excellent pitting resistance and wear resistance. Fatigue and impact strength are equivalent to conventional carburized steels. Cold-formability and machinability of the new steel are adequate for manufacturing gears because of its ordinary hardness before carburizing. The new steel has already been put to practical use in automatic transmission gears. Application test results are also reported.

An engine cycle simulation code with detailed chemical kinetics has been developed to study Homogeneous Charge Compression Ignition (HCCI) combustion with hydrogen as the fuel. In order to attain adequate combustion duration, resulting from the self-accelerating nature of the chemical reaction, fuel and temperature inhomogeneities have been brought to the calculation by considering the combustion chamber to have various temperature and fuel distributions. Calculations have been done under various conditions including both perfectly homogeneous and inhomogeneous cases, changing the degree of inhomogeneity. The results show that intake gas temperature is more dominant on ignition timing of HCCI than equivalence ratio and that there is a possibility to control HCCI by introducing appropriate temperature inhomogeneity to in-cylinder mixture.

This paper deals with the development of plastics recycling technology, which is one key to resolving environmental and natural resource problems and encouraging recycling activities. Bumpers are among the heaviest plastic auto parts, so the technology for recycling bumpers is strongly required. Paint remaining on bumpers causes the strength of the recycled material to decline and degrades its surface quality. Therefore, unless the paint is removed, it is impossible to use recycled material to manufacture new bumpers. This hampers recycling efforts and results in low-value recycled material. Consequently, it is essential to develop a simple paint removing without chemical substances for practical plastics recycling at low cost. Two topics are discussed in this paper. The first concerns the mechanism of paint removal and the development of a technique for utilizing that mechanism.

Hypereutectic Al-Si alloy 390, containing large amounts of hard silicon particles, has mainly been used for wear-resistant alloy applications. In the case of hypereutectic Al-Si alloys, the primary silicon particle size and distribution must be controlled to obtain stable wear resistance. The service life of furnaces and molds is shortened by the high melting and casting temperatures required for controlling primary silicon. Furthermore, machinability is degraded by large primary silicon particles. To overcome these problems, a new wear-resistant Al-Si alloy has been developed which provides good castability and machinability. This alloy also has wear resistance and mechanical properties similar to those of the 390 alloy. Specifically, the problems regarding castability and machinability were solved by decreasing the silicon content of the 390 alloy, but that also reduced wear resistance.

Down-gauging outer panels is an effective method for reducing the weight of an automobile body. We have succeeded in narrowing the thickness of outer panels by using rib-shaped plastic reinforcement. The plastic reinforcement consists of unhardened resin and an adhesive sheet, and it conforms well to the curved panel surface. In the body paint oven, it is hardened on the outer panels and forms a rib-shaped structure. This paper describes the composition of the resin material, the manufacturing process and the strength and rigidity of outer panels made with the rib-shaped reinforcement. It also discusses the weight reduction effect achieved by applying these panels to the doors of a production vehicle.