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This study concerns a dissimilar materials joining technique for aluminum (Al) alloys and steel for the purpose of reducing the vehicle body weight. The tough oxide layer on the Al alloy surface and the ability to control the Fe-Al intermetallic compound (IMC) thickness are issues that have so far complicated the joining of Al alloys and steel. Removing the oxide layer has required a high heat input, resulting in the formation of a thick Fe-Al IMC layer at the joint interface, making it impossible to obtain satisfactory joint strength. To avoid that problem, we propose a unique joining concept that removes the oxide layer at low temperature by using the eutectic reaction between Al in the Al alloy and zinc (Zn) in the coating on galvanized steel (GI) and galvannealed steel (GA). This makes it possible to form a thin, uniform Fe-Al IMC layer at the joint interface. Welded joints of dissimilar materials require anticorrosion performance against electrochemical corrosion.

In recent years, the temperature of automobile exhaust gas is on a rising trend due to lowering pollutant emissions and improving fuel economy, and exhaust gas temperature reaches as high as 1173K in the case of diesel engine cars. Against this background, Ni-resist D-5S cast iron has been chosen extensively as a turbine housing material for the diesel engine cars. But, Ni-resist D-5S has become a material of great cost volatility due to high Nickel content of 35 mass%, which price is expensive and unstable. On the contrary Ferritic cast steels, which possesses favorable thermal fatigue properties and good material cost stability, are considered to be promising substitutions for the Ni-resist D-5S. However conventional ferritic cast steels have relatively high melting points, which cause poor castability.

The demands on valve seat insert materials, in terms of providing greater wear-resistance at higher temperatures, enhanced machinability and using non-environmentally hazardous materials at a reasonably low cost have intensified in recent years. Due therefore to these strong demands in the market, research was made into the possibility of producing a new valve seat insert material. As a result a high speed steel based new improved material was developed, which satisfies the necessary required demands and the evaluation trials, using actual gasoline engine endurance tests, were found to be very successful.

Application of microalloyed steel to automobile parts is becoming increasingly common in Japan. However, fatigue properties of actual automotive forged parts with slight notches on their surface have not been fully clarified. In this work, the fatigue properties of microalloyed steel were studied using test specimens and also actual automotive parts. The results indicated that microalloyed steel with an optimal microstructure showed higher notch fatigue resistance than quenched-tempered steel. The improvement of material technology and the application of microalloyed steel have not only served to bring product costs down, but have paved the way for part weight reductions. Lightweight connecting rods for the newly developed Nissan engines have been produced, contributing to improved engine performance.

In Europe and the U.S., fracture split connecting rods are used in many types of current engines. This process can eliminate the machining of crankshaft end and eliminate the dowel pin for positioning. The most important key for fracture split connecting rods is a reduction in the plastic deformation during the fracture splitting process. For this reason, sinter-forged materials and pearlitic steels (C70S6) are used for fracture split connecting rods because of their low ductility. Such types of steel, however, are inferior to the hot forged microalloyed steels typically used as connecting rod material in Japan in terms of buckling strength and machinability although they are easier to fracture split. On the other hand, the conventional microalloyed steels used for connecting rods in Japan are not suitable for fracture splitting. The reason is that these steels have too much ductility and associated plastic deformation for fracture splitting.

In recent years, the use of aluminum die cast parts in automobile manufacturing has increased due to greater demand for automotive weight reduction. For even wider application, it is necessary to reduce manufacturing costs and improve product quality. Finite element method (FEM) analysis suggested that a new material, featuring 50% improved thermal conductivity within the working temperature of the die compared to the conventional 5% chromium hot work tool steel AISI-H13 (H-13), would decrease thermal stress on the die surface and lower the maximum surface temperature. As a result, the reduced stress should increase the die service life with respect to heat checks. At the same time, the reduced surface temperature should increase the cooling rate of die cast products, which will in turn improve product quality due to finer structure formation.

To reduce quenching distortion, step gas quenching has been proposed in recent years, which refers to rapid gas cooling of steel from austenitizing temperature to a point above or below Ms temperature, where it is held for a specific period of time, followed by gas cooling. In this study, by using infrared thermography combined with conventional thermocouple, a new temperature monitoring and control system was developed to realize the step gas quenching process of a hypoid ring gear after low pressure carburizing. The test production results indicate that by using the new monitoring and control system, we can control the gas quenching process and the distortion of carburized gear treated by step gas quenching can be reduced significantly compared with standard gas quenching.

SUS301-EH is widely used as a material for exhaust system gaskets, however, at temperatures in excess of 400°C, it can not be used as gas-seal ability of the material declines due to its reduced hardness. The following methods were found to be effective in controlling the softening of stainless steel at high temperatures: (1) The addition of a nitrogen component; (2) Stabilization of the austenite structure; (3) The addition of a molybdenum component. The addition of 0.5% nitrogen to austenitic stainless steel containing molybdenum has enabled the speed of softening at high temperatures to be significantly reduced, due to strain aging by solid nitrogen below 600°C and the combined effects of precipitation hardening and control of growth of recrystallized grains through the precipitation of fine Cr2N on the dislocations and the grain boundary above 600°C.

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.

A free machining Pb-free steel was developed with shape controlled sulfide (SCS) for use in automobile applications such as rocker arms and crankshafts. This free-machining steel is characterized by its improved chip breakability, for which a technique that adds very small quantities of Ca and Ti to control sulfide shape was specifically applied. It was confirmed that this free-machining steel can offer almost equivalent machinability and equivalent or higher fatigue strength by comparison with Pb-added steel for use in rocker arms or crankshafts with S and Ti modifications.

This paper presents the results of a strength analysis of a newly developed steel structure featuring a special cross section achieved with the hydroforming process that minimizes the influence of springback. This structure has been developed in pursuit of further weight reductions for the steel body in white. A steel tube with tensile strength of 590 MPa was fabricated in a low-pressure hydroforming operation, resulting in thicker side walls. The results of a three-point bending test showed that the bending strength of the new steel structure with thicker side walls was substantially increased. A finite element crush analysis based on the results of a forming analysis was shown to be effective in predicting the strength of the structure, including the effect of work hardening.

As trends of automobile engine exhaust gas temperature are reducing emissions, the material for the exhaust components have been changed from ductile irons to ferritic cast alloys or stainless steel, further to austenitic cast alloys for higher performance engines. The current austenitic alloys, however, have thermal fatigue failure over 1273K. The authors developed excellent thermal fatigue resistant austenitic cast alloys, by investigating the effects of alloying elements on strength and thermal expansion, which correlate with thermal fatigue property. Developed alloys are expected to apply to exhaust components at gas temperatures over 1273K.

Ferritic stainless steel gas metal arc welding (GMAW) wires have been widely using for automotive exhaust system components made of ferritic stainless steels. In order to enhance the high temperature strength of weld metal, it is necessary to make the microstructure of weld metal finer. In this study, the effect of the chemistry of ferritic stainless steel GMAW wire on the weld metal microstructure was investigated and new ferritic stainless steel GMAW wire providing fine grain microstructure of the weld metal was developed to improve high temperature mechanical properties, oxidation resistance, corrosion resistance of the weld metal and weldabiliy of the wire.

Improving the impact strength of the differential gears is one way to reduce the size and weight of the final drive unit. Previously, we developed high-strength steel for gear use by adding molybdenum and reducing impurities such as phosphorus and sulfur. However, additional improvement of impact strength is required these days due to higher engine torque and demands for further weight reductions. Toward that end, we focused on boron, which has been used as an element for improving hardenability, and analyzed what effect its addition would have on impact strength. Useful knowledge was obtained for improving impact strength through enhancement of grain boundary toughness. Various steels were then produced experimentally and used in gear strength tests. The results made it possible to improve impact strength while reducing the content of other alloys, resulting in the development of a chromium-molybdenum-boron case hardening steel with superior cold forgeabilty.

Although shot peening is an old technology, it has been revived in the Japanese automotive industry as a means to enhance the fatigue durability of steel components. Particular emphasis is on the application of “hard shot peening”. “Hard shot peening” is a high intensity peening technology which results in a higher magnitude of compressive residual stress and, therefore, greater fatigue resistance than conventional shot peening. The first area of development was in high performance carburizing steels suitable for hard shot peening. Desirable traits were enhanced by reducing the carburizing anomalies resulting from intergranular oxidation and by the enhancing case toughness. Further improvement of fatigue resistance has been accomplished by dual peening, first with hard shot followed by smaller diameter steel shot at a lower intensity. This paper also describes the development of long life shot media for hard shot peening.

High strength transmission gears have been developed for use in the final gear set of front-wheel-drive vehicles. The steel used as the gear material has a higher molybdenum content, allowing more austenite to be retained following carburizing than is possible with chromium steel. As a result, the steel can be subjected to higher intensity shot peening by using harder peening particles which are projected by an air-nozzle peening system. With this procedure, the fatigue strength of the gears can be increased 1.6 times over that of conventional gears.

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.

There are strong demands for vehicle weight reductions so as to improve fuel economy. At the same time, it is also necessary to ensure crash safety. One effective measure for accomplishing such both requirements conflicting each other is to apply advanced high strength steel (AHSS) of 780 MPa grade or higher to the vehicle body. On the other hand, higher strength steels generally tend to display lower elongation causing formability deterioration. Nissan Motor Corporation have jointly developed with steel manufacturers a new 980 MPa grade AHSS with high formability with the aim of substituting it for the currently used 590 MPa grade high-tensile steel. Several application technologies have been developed through the verifications such as formability, resistance spot weldability, crashworthiness, and delayed fracture.

The influence of chemical compositions and forging conditions on mechanical properties of forged bainitic steels were studied. Manganese and chromium are useful to produce bainite structure while carbon and vanadium are good to control the mechanical properties of the steels. One of the compositions is 0.25 % C - 2.1 % Mn - 0.7 % Cr - 0.15 % V of which tensile strength is 1000 MPa and impact value (2 mm U type notched specimen) is 50 J/cm2 for 100 mm diameter bars. Bainitic steels have lower fatigue limit in the case of smooth specimen than ferrite-pearlite microalloyed steels but have higher fatigue limit in the case of notched specimen.

Surface roughness of steel sheet for automotive use is one of the most important control items, because the surface roughness influences image clarity of painted surface, press formability and easiness in handling during manufacturing and processing of steel sheets. Laser texturing technology is introduced into a roll finishing process of cold rolling, and new type of regular surface roughness profile can be processed on the surface of steel sheets. Effective application method of this technology is investigated at the present day. In Japan, Laser-textured dull steel sheets are used for outer-panels of automotive body as the first application. And image clarity after painting of outer panels has been successful in improving. Nowadays, Laser texturing technology is actually used for manufacturing the high image clarity steel sheets, and they are manufactured in large quantities. Another application of Laser texturing technology is for the inner parts which require pressformability.