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Standard

ENGINE OIL PUMP PERFORMANCE AND DURABILITY TEST PROCEDURES
2023-03-23
CURRENT
USCAR46
SAE/USCAR-46 defines test methods and outputs for engine oil pump bench testing. Performance and durability testing are the primary focus of this standard. This is written to specifically address testing of electronically controlled variable displacement pumps but can be adapted to mechanically controlled pumps and other pump technologies as needed. This standard outlines critical inputs and outputs in order to perform the testing and report results, but does not specifically set the acceptance standards or pass/fail criteria. Acceptance criteria must be set by the customer.
Standard

PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS
2022-06-30
CURRENT
USCAR2-8
This specification covers performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in road vehicle applications that are: low voltage (0 to 20 VDC) or Coaxial. Incomplete (mechanical) specifications for jacketed twisted pair connectors are also provided. These procedures are only applicable to terminals used for In-Line, Header, and Device Connector systems. They are not applicable to Edge Board connector systems, twist-lock connector systems, >20 VAC or DC, or to eyelet terminals. No electrical connector, terminal, or related component may be represented as having met USCAR specifications unless conformance to all applicable requirements of this specification have been verified and documented. All required verification and documentation must be done by the supplier of the part or parts.
Standard

PERFORMANCE SPECIFICATION FOR MINIATURE AUTOMOTIVE COAXIAL CONNECTORS
2022-05-10
CURRENT
USCAR49
This document contains procedures for performance testing of electrical terminals, connectors, and components for coaxial-style cable with an outside cable diameter of 3.6mm and smaller. These are often called “Mini Coax connector systems.” This specification applies to coaxial cable connection systems that operate at frequencies from DC to 9 GHz and are intended for road vehicles. The characteristic impedance of the Mini-Coax connection system described here is 50 ohms, however nothing excludes the use of these connectors in systems with a different characteristic impedance. This specification applies only to connection systems using coaxial cable.
Standard

AUTOMOTIVE GRADE COAXIAL CABLE PERFORMANCE SPECIFICATION
2022-03-15
CURRENT
USCAR29-1
This document specifies dimensional, functional and visual requirements for Automotive grade coaxial cable. This material will be designated AG for general-purpose automotive applications or AG LL for low loss applications. It is the responsibility of the user of this cable to verify the suitability of the selected product (based on dimensional, mechanical, electrical and environmental requirements) for its intended application. It is the responsibility of the supplier to retain and maintain records as evidence of compliance to the requirements detailed in this standard.
Standard

TEST PROCEDURE FOR ELECTRICAL GROUND ATTACHMENTS
2022-02-25
HISTORICAL
USCAR26
This test procedure is intended to evaluate and/or validate electrical ground schemes for use on the body or chassis. There are two classes based on the expected environmental conditions. Exposed Grounds can be located anywhere in the vehicle (except on the powertrain) and is the class for which most schemes should be tested. Unexposed Grounds can only be used in the passenger compartment or trunk and as such are special cases. This procedure as written is not intended for testing powertrain grounds where high temperatures and vibration levels may be encountered. These situations may require modifications to this procedure and are left to the Responsible Engineer to determine. This specification does not specifically address validation of terminal to wire electrical crimps. Crimps are tested to SAE/USCAR-21
Standard

COAXIAL CABLE CONNECTOR INTERFACE - SQUARE OUTER CONDUCTOR
2021-08-05
CURRENT
USCAR19-2
This radio frequency (RF) connector interface specification is suited for unsealed automobile applications up to 2 GHz. Dimensional requirements are specified in this document to ensure interchangeability. This RF connector interface specification is intended for in-line, board mount, device mount, straight or angled applications. Performance requirements are specified in SAE/USCAR-2, and in SAE/USCAR-17.
Standard

TEST PROCEDURES FOR EVALUATING BOLT-LOAD RETENTION OF MAGNESIUM ALLOYS
2020-11-19
CURRENT
USCAR35-1
A bolt-load retention (BLR) test is a practical test to determine the bolt load of a fastener joint with time and at given temperatures. There are three types of BLR tests described in this standard, namely general-purpose test, design-purpose test, and screening material test. A general-purpose BLR test may be used for screening materials, while a design-purpose BLR test is usually used to verify the BLR behavior of a specific joint. The screening material test is an example of the general-purpose test for typical automotive applications.
Standard

TORQUE-TENSION TESTING AND EVALUATION OF FASTENER FINISHES
2020-11-19
CURRENT
USCAR11-2
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

TEST FOR EVALUATING THE TORQUE-TENSION RELATIONSHIP OF BOTH EXTERNAL AND INTERNAL METRIC THREADED FASTENERS
2020-11-19
CURRENT
USCAR10-3
This standard provides a test method for determining the torque-tension relationship of both external and internal metric threaded fasteners for the purpose of measuring the frictional characteristics of the threaded fasteners. The results obtained by this test are relevant to the test conditions only and should not be utilized for specific applications.
Standard

DEEMBRITTLEMENT VERIFICATION TEST
2020-11-19
CURRENT
USCAR7-2
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

LEAD-FREE SOLDER VALIDATION TEST PLAN
2020-11-19
CURRENT
USCAR40-2
This guideline is applicable to existing lead solder production products that will change to lead-free solder processes to meet the ELV Directive 2000/53/EC Annex II, exemption 8B requirements. This guideline is applicable to similar products used by multiple OEM's that have the same manufacturing processes / equipment. The intent is to streamline the supplier’s environmental testing via common qualification to reduce timing, quantities, and costs.
Standard

PERFORMANCE SPECIFICATION FOR CABLE-TO-TERMINAL ELECTRICAL CRIMPS
2020-01-22
CURRENT
USCAR21-4
This specification defines test methods and requirements for validation of solderless crimped connections. The purpose of this test is to simulate in the lab the stress seen in a typical life (15 years and 150000 miles) for a crimp connection and assure the crimp is mechanically strong and electrically stable. This specification was developed for use with stranded automotive copper wire. Only where specifically mentioned are other constructions or other core materials (aluminum, clad, steel core, etc.) applicable. This specification does not apply to wire types not mentioned, such as coaxial cable crimps, unless a USCAR-21 test is specifically referenced in the test specification for that wire type. This specification is based on accepted levels of environmental exposure for automotive applications.
Standard

GRAIN FLOW PATTERN FOR BOLTS, SCREWS, AND STUDS
2019-03-14
CURRENT
USCAR8-4
This specification covers the grain flow pattern requirements in headed bolts, screws, and studs. The heading practice in the manufacture of the bolt, screw, or stud sets the grain flow pattern, but it is also greatly influenced by the fastener and tooling design as well as cold-forging setup. The use of tooling design simulation software is recommended and a commonly used practice that provides reliable forging predictions for superior grain flow quality.
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

ROAD VEHICLES – 60 V AND 600 V SINGLE CORE (ISO/METRIC) CABLES – DIMENSIONS, TEST METHODS AND REQUIREMENTS
2017-07-13
CURRENT
USCAR23-1
This International Standard specifies the dimensions, test methods, and requirements for single core 60 V cables intended for use in road vehicle applications where the nominal system voltage is ≤ (60 V DC or 25 V AC). It also specifies additional test methods and/or requirements for 600 V cables intended for use in road vehicle applications where the nominal system voltage is > (60 V DC or 25 V AC) to ≤ (600 V DC or 600 V AC). It also applies to individual cores in multi-core cables. See ISO 6722 for “Temperature Class Ratings”.
Standard

PERFORMANCE SPECIFICATION FOR AUTOMOTIVE WIRE HARNESS RETAINER CLIPS
2017-05-10
HISTORICAL
USCAR44
This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Typical plastic retainers work by having a set of “branches” that can be inserted into a hole sized to be easy to install but provide acceptable retention. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. This specification has several test options to allow the test to match to the expected service conditions. The variability of applications typically arises a) from different ambient temperatures near the clip, different proximity to automotive fluids, different exposure to standing water or water spray and different thicknesses of the holes that the clip is inserted into.
Standard

PERFORMANCE SPECIFICATION FOR ULTRASONICALLY WELDED WIRE TERMINATIONS
2016-04-05
HISTORICAL
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.
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