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Two working groups in the JSAE Committee of Fatigue–Reliability Section1 are currently researching the issue of fatigue life by both experimental and the CAE approach. Information regarding frequent critical problems on arc–welded structures were sought from auto–manufacturers, vehicle component suppliers, and material suppliers. The method for anti–fatigue design on arc–welded structures was established not only by a database created by physical test results in accordance with the collected information but also with design procedure taking Fracture–Mechanics into consideration. This method will be applied to vehicle development as one of the virtual laboratories in the digital prototype phase. In this paper, both the database from bench–test results on arc welded structures and FEA algorithm unique to JSAE are proposed some of the analysis results associated with the latter proposal are also reported.

When CNG, LPG, and other gas fuels were used for combustion in vehicles' engines, a large degree of valve seat wear was observed and it was difficult to provide the same wear resistance as for gasoline engines. Therefore, the mechanism of valve seat wear in gas fuel engines was analyzed and an alloy valve seat was developed. In addition to converting the matrix to an alloy, Co-Mo-Cr was used for the self-lubricating effect present in its hard particles. Also, in order to improve machinability, which is inversely related to wear resistance, a sintered alloy valve seat containing MnS was developed. As a result, wear resistance equal to that for gasoline engines was achieved.

Detergent additives in automotive gasoline fuel are mainly designed to reduce deposit formation on intake valves and fuel injectors, but it has been reported that some additives may contribute to CCD formation. Therefore, a standardized bench engine test method for CCDs needs to be developed in response to industry demands. Cooperative research between the Petroleum Association of Japan (PAJ) and the Japan Automobile Manufacturers Association, Inc. (JAMA), has led to the development of a 2.2L Honda engine dynamometer-based CCD test procedure to evaluate CCDs from fuel additives. Ten automobile manufacturers, nine petroleum companies and the Petroleum Energy Center joined the project, which underwent PAJ-JAMA round robin testing. This paper describes the CCD test development activities, which include the selection of an engine and the determination of the optimum test conditions and other test criteria.

The orientation of electrodeposited Pb alloy crystal was related to the morphology of the deposits, and the orientated electrodeposits of a Pb alloy mainly consisting of the (h00) plane have exhibited a good wetness characteristic for lubricant oil. As a result, the orientated electrodeposits of this Pb alloy used in the overlay of bearings has an anti-seizure parameter (PV) at least 30% higher than that of conventional deposits in terms of the sliding characteristic. The sintered lead-bronze alloy used as the bearing's lining material offers good fatigue strength, which was made possible by adopting a newly developed Cu-Sn alloy matrix and reducing the amount and grain size of the Pb phase. Studies on plane bearings of high performance have clarified through bearing characteristic and engine firing tests that combining the orientated Pb alloy overlay and strengthening the lining increases the anti-seizure property and improves durability with regard to bearing fatigue and wear.