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Technical Paper

Development and Validation of a Reduced Chemical Kinetic Mechanism of Dimethyl Carbonate and Ethylene Carbonate

2024-04-09
2024-01-2085
With the rapid development of electric vehicles, the demands for lithium-ion batteries and advanced battery technologies are growing. Today, lithium-ion batteries mainly use liquid electrolytes, containing organic compounds such as dimethyl carbonate and ethylene carbonate as solvents for the lithium salts. However, when thermal runaway occurs, the electrolyte decomposes, venting combustible gases that could readily be ignited when mixed with air and leading to pronounced heat release from the combustion of the mixture. So far, the chemical behavior of electrolytes during thermal runaway in lithium-ion batteries is not comprehensively understood. Well-validated compact chemical kinetic mechanisms of the electrolyte components are required to describe this process in CFD simulations. In this work, submechanisms of dimethyl carbonate and ethylene carbonate were developed and adopted in the Ansys Model Fuel Library (MFL).
Technical Paper

Parameter Optimization and Characterization of Aluminum-Copper Laser Welded Joints

2024-04-09
2024-01-2428
Battery packs of electric vehicles are typically composed of lithium-ion batteries with aluminum and copper acting as cell terminals. These terminals are joined together in series by means of connector tabs to produce sufficient power and energy output. Such critical electrical and structural cell terminal connections involve several challenges when joining thin, highly reflective and dissimilar materials with widely differing thermo-mechanical properties. This may involve potential deformation during the joining process and the formation of brittle intermetallic compounds that reduce conductivity and deteriorate mechanical properties. Among various joining techniques, laser welding has demonstrated significant advantages, including the capability to produce joints with low electrical contact resistance and high mechanical strength, along with high precision required for delicate materials like aluminum and copper.
Technical Paper

Advanced Aftertreatment System Meeting Future HD CNVII Legislation

2024-04-09
2024-01-2379
Options for CNVII emission legislation are being widely investigated in a national program organized by China Vehicle Emission Control Center (VECC) since early 2020. It is foreseen that this possibly last legislation in China will have more stringent emission requirements compared to CNVI, including among other changes especially a further reduction of nitrogen oxide (NOx), inclusion of nitrous oxide (N2O) and sub-23 nm particle number (PN). This study investigates the technical feasibility to fulfill a CNVII emission legislation scenario, based on a modified CNVI 8 L engine operating under both cold and hot World Harmonized Transient Cycle (WHTC) and Low Load Cycle (LLC).
Standard

Motor Vehicle Brake Fluid

2024-03-12
CURRENT
J1703_202403
This SAE Standard covers motor vehicle brake fluids of the nonpetroleum type, based upon glycols, glycol ethers, and appropriate inhibitors, for use in the braking system of any motor vehicle such as a passenger car, truck, bus, or trailer. These fluids are not intended for use under arctic conditions. These fluids are designed for use in braking systems fitted with rubber cups and seals made from styrene-butadiene rubber (SBR), or a terpolymer of ethylene, propylene, and a diene (EPDM).
Standard

Motor Vehicle Brake Fluid Based Upon Glycols, Glycol Ethers, and the Corresponding Borates

2024-03-12
CURRENT
J1704_202403
This SAE Standard covers motor vehicle brake fluids of the nonpetroleum type, based upon glycols, glycol ethers, and borates of glycol ethers, and appropriate inhibitors for use in the braking system of any motor vehicle, such as a passenger car, truck, bus, or trailer. These fluids are not intended for use under arctic conditions. These fluids are designed for use in braking systems fitted with rubber cups and seals made from styrene-butadiene rubber (SBR) or a terpolymer of ethylene, propylene, and a diene (EPDM).
Technical Paper

A Study on the Thermal Interface Mechanisms of Natural Fiber/Fillers and Allotrope-Based Polymers

2024-02-23
2023-01-5129
Composites of polymers reinforced with synthetic/natural fibers are mainly used in engineering sectors such as automobiles, aerospace, and in household appliances due to their abrasion resistance, high toughness, strength, and high specific modulus. The purpose of this research is to provide an overview of fiber-matrix interfaces and interface mechanism that leads to enhanced properties. This article investigates how natural/synthetic fibers, mineral based-materials and additional allotropic materials work rapidly and effectively across interfaces.
Technical Paper

Investigation of Inconel 718 on Electrical Discharge Machining Using Copper and Copper Alloy-Tungsten Disulfide Electrodes

2024-02-23
2023-01-5149
Inconel 718 is a nickel-rich superalloy that can function in cryogenic to high-temperature applications. It has excellent mechanical and corrosion-resistant properties. This research focuses on developing Cu and Cu–alloy–tungsten disulfide (WS2) tools developed through a stir casting route, and the machining behaviour of Inconel 718 alloy in the EDM Process is investigated. The influence of output responses of Removal rate of material (RRM), surface roughness (SR), and tool wear loss rate (TWR) on input constraints pulse time-on, peak discharge current, and type of tool. The optimal parameters are studied with the aid of the Response Surface Methodology (RSM) and Analysis of Variance (ANOVA) combination, in response to maximize and decrease the RRM, TWR, and SR, respectively. It is found that using the Cu-WS2 tool provides an optimum finding with a peak discharge current of 18 Amps, and pulse on time of 8 μs yields the best value for RRM, TWR, and SR.
Technical Paper

Irradiation with High Energy Electron Beams Increases the Hardness of Metamorphic Copper-Based Alloys

2024-02-23
2023-01-5131
This study delves into the innovative realm of synthesizing surface alloyed materials by utilizing copper-based metamorphic powders subjected to high-intensity electron beam irradiation. The process involves depositing metamorphic particles onto a stainless-steel substrate, and subsequently exposing the assembly to a powerful electron beam, resulting in the development of distinct surface alloyed layers. A notable advancement was achieved by introducing a second layer of metamorphic powders over the existing alloyed layer, followed by further treatment with the electron beam. The alloyed layers, characterized by a volumetric concentration ranging from 60 to 67%, exhibited a fascinating phenomenon— the formation of abundant borate crystals with the chemical formula Al2.56Fe1.75Ni0.84. This crystal presence significantly elevated the hardness of the surface alloyed layers, showcasing an impressive five to sevenfold increase compared to the substrates.
Technical Paper

Structure and Behaviour Characteristics of Aluminum –Nickel- Zinc Alloy by Spray Forming

2024-02-23
2023-01-5120
The microstructure of the alloy and the manner in which it responds to heat treatment has been investigated. The alloy was aged at 550OC when it was initially spray-formed, or when its thickness was decreased by 38%. Before further aging of some specimens, a four-hour solution treatment at 1015OC was performed. The subsequent phase was a cold deformation that was barely 60% of the sample's initial thickness. The alloys' electrical conductivity and hardness may be evaluated based on how long they had been created. Following solution treatment and cold rolling, the alloy's peak hardness was around 380 kgf/mm2. In samples aged immediately under spray-produced conditions, the maximum peak hardness of 255 kgf/mm2 was attained. Conductivities in freshly cold-rolled samples could reach up to 75% of the standard for annealed copper internationally. It looks at the microstructural features of this alloy in this context, paying close attention to how various processing conditions affect them.
Technical Paper

Characteristics Enhancement of Mechanical Properties of Aluminum Metal Matrix Composites Reinforced with Silicon Carbide Using Stir Casting Technique

2024-02-23
2023-01-5164
Metal Matrix Composites (MMC) made of the aluminium as base metal is now being used in diversed applications due to its extended properties. The physical, chemical, mechanical and structural properties make it as irresistible in the engineering applications. Metal Matrix Composites (MMCs) based on aluminium have increased in popular in various applications including aerospace, car, space, transportation, and undersea applications.. In this study, Al LM25/SiCp MMC was fabricated using a low-cost stir casting technique, and the weight percentage of SiCp was varied from 4% to 8% to prepare the MMC plates. The aim of the research was to investigate the mechanical properties of the specimen, including hardness, tensile, and impact tests. The microstructure of the specimens is investigated which shows the bonding between the particles which is fabricated by Stir casting method. The sample 2 has better mechanical properties when it is compared with other specimens.
Technical Paper

A Study on Different Chemical Treatments for Natural Fiber Reinforced Composites

2024-02-23
2023-01-5179
The aim of this study is to examine the effects of chemical treatments on the performance of composites that are reinforced with natural fibres. Natural fibres have several advantages, such as low density, low cost, and environmental friendliness, as they can be biodegraded or recycled. However, natural fibre composites also have some limitations, such as their poor compatibility with the matrix material and the reinforcement material. This leads to weak interfacial bonding and poor mechanical properties. Another problem with natural fibres is that they absorb more moisture than other materials, which can affect their dimensional stability and durability. Therefore, this research compares the compatibility of different chemical treatments that can modify the surface properties of natural fibres and improve their adhesion with the matrix and reinforcement.
Standard

Chemical Compositions of SAE Carbon Steels

2024-02-23
CURRENT
J403_202402
In 1941, the SAE Iron and Steel Division, in collaboration with the American Iron and Steel Institute (AISI), made a major change in the method of expressing composition ranges for the SAE steels. The plan, as now applied, is based in general on narrower cast or heat analysis ranges plus certain product analysis allowances on individual samples, in place of the fixed ranges and limits without tolerances formerly provided for carbon and other elements in SAE steels. For years the variety of chemical compositions of steel has been a matter of concern in the steel industry. It was recognized that production of fewer grades of steel could result in improved deliveries and provide a better opportunity to achieve advances in technology, manufacturing practices, and quality, and thus develop more fully the possibilities of application inherent in those grades.
Technical Paper

Effectiveness of Thermal and Mechanical Properties of Jute Fibers under Different Chemical Treatment for Automotive Interior Trim

2024-01-22
2024-01-5008
In the quest for sustainable materials for automotive interior trim, jute fiber is gaining traction due to its characteristics, which align with other renowned natural fibers. This study aimed to assess the efficacy of sodium bicarbonate as a treatment for jute fibers in comparison to conventional alkaline treatments. Both treated and untreated fibers were examined. Results showed that alkali-processed fibers demonstrated enhanced crystallization, thermal resistance, and surface quality relative to untreated ones. Specifically, alkali-treated jute fibers exhibited a degradation onset at 261.23°C, while those treated with sodium bicarbonate began degrading at 246.32°C. Untreated fibers had a degradation onset at 239.25°C. Although both treatments improved the thermal stability of the fiber, sodium bicarbonate processing, while beneficial, was slightly less effective than the traditional alkaline method.
Technical Paper

Effect of Busbar Design on the Thermal Performance of Battery Packs

2024-01-16
2024-26-0135
Li-ion batteries face challenges that are not usually present with other chemistries is cell balancing. If a high imbalance occurs within a parallel circuit, possibly because of poor cell - grading or due to temperature localization, the adjacent cells will charge the unbalanced cell and it may be possible that the imbalance never completely fades away and the other cells also end up unbalanced. One of the key solutions to maintaining cell balance is to ensure that all cells within a battery pack are kept at a uniform temperature. This requires careful thermal management, which can be achieved through a combination of conduction and convection circuits. In this paper, a 1D-3D simulation study has been performed on a 12V 4s-4p pack by varying the thickness of HV busbars and temperature localization effects and temperature uniformity has been observed. The holder has 16 cells with a 4×4 grid pattern, each cell has a diameter of 18 mm and a length of 65 mm.
Technical Paper

A systematic review on smart coatings for automotive applications

2024-01-08
2023-36-0126
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.
Technical Paper

Potential Application of Rubber-Graphene Compounds in the Automotive Parts

2024-01-08
2023-36-0028
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.
Technical Paper

Investigations on the Effects of Chemical Treatment on Mechanical Properties of Thespesia Lampas Fiber Reinforced Composites for Automobile Applications

2023-11-10
2023-28-0121
In today's world, there is an increasing emphasis on the responsible use of fiber reinforced materials in the automobile applications, construction of buildings, machinery, and appliances as these materials are effectively reused, recycled, or disposed with minimum impact on the environment. As such, it has become mandatory to incorporate sustainable, environmental friendly and green concepts in the development of new materials and processes. The primary objective of this study is to manufacture composites using fibers obtained from Thespesia Lampas plants, which are known for their soft, long fibers that are commonly used in various domestic products. The composites are made by combining these fibers with a general purpose polyisocyanurate resin, and their potential applications in both domestic and commercial products are explored. To evaluate the properties of these composites, tests are conducted for tensile strength, flexure, and water absorption.
Technical Paper

A Comparative Analysis on Corrosion Behavior on Precipitation Hardened Stainless Steel Weldments for Car Parts

2023-11-10
2023-28-0149
Precipitation Hardened Stainless Steel (PHSS) is one of the martensitic steels that possess exceptional strength and corrosion resistance. Because of its characteristics, this PHSS is exclusively adopted in numerous engineering uses such as nuclear, chemical and marine industries. Welding is one of the important methods of joining that helps to make weldments with better performance characteristics. Corrosion behaviour is one of the important characteristics that contribute hugely to marine and other corrosion-related environments and also this is the most common problem for most of the manufacturing industries. The goal of this study was to analyze the PHSS weldments’ corrosive behavior and compare it with that of the two commonly used welding processes, namely MIG and TIG. The corrosive properties of the weldments were evaluated using various mediums, such as nitric acid, ferric chloride, and Oxalic acid.
Technical Paper

“Experimental Investigation on the Properties of Briquettes Made from Ideal Municipal Waste: An Alternate Fuel”

2023-11-10
2023-28-0060
Energy demand climbs as a consequence of the inherent relationship between the rate of consumption of energy and the growth of the economy. In light of the depletion of fossil fuels, it is necessary to implement energy efficiency techniques and policies that support sustainable development. Globally, researchers show more interest in discovering fossil fuel alternatives, as a result of fuel crisis. This research elaborates on the production and experimental investigation of briquettes made from ideal municipal solid waste (MSW), such as food waste and garden waste, as a feasible choice for alternate fossil fuels. From Municipal, agricultural, and food waste, we can get biomass waste. Municipal solid and agricultural waste is extensively dispersed, but their potential for converting biomass into energy generation still needs to be explored. This study was carried out based on the information gathered from various studies published in the scientific literature.
Technical Paper

Effect of Temperature on Synchronizer Ring Performance

2023-11-10
2023-28-0054
The brass synchronizers are not resistant to abusive conditions of gearbox operations, but they are very durable and cheap when used on their favorable material property working limit. The main failure which can occur in the gearbox due to the synchronizer is crash noise. During gear shifting the gear crash will create high discomfort for the driver and must apply high force to change the gears. The main factors which contribute to the crash phenomenon are the insufficient coefficient of friction, high drag in the system, and high wear rate of the synchronizer rings before the intended design life of the synchronizer. The brass synchronizers were tested on the SSP-180, ZF synchronizer test rig to know the effect of the synchronizer performance parameters like the coefficient of friction, sleeve force, slipping time as well as durability parameters like wear rate when the operating temperature of the oil is changed.
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