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Technical Paper

Application of Shape Memory Heat Engines to Improving Vehicle Fuel Economy

1996-04-01
91A128
Shape memory materials undergo temperature-induced martensitic phase transformations that involve reversible dimensional changes. In performing these changes in shape, the shape-memory material is able to do work against external constraints, and this is the basis for shape-memory low-temperature heat engines. The transformation temperatures on heating and cooling are often not very different (little hysteresis) and are well defined and reproducible. Furthermore, these temperatures can be adjusted by varying the composition of the shape memory alloy. Internal combustion engines dissipate approximately two-thirds of the fuel energy as heat to the exhaust and coolant systems. A low-temperature heat engine could convert a fraction of this heat energy to useful work. This paper discusses the conceptual basis for the application of shape memory heat engines to internal combustion engine powered vehicles. Metallurgical and thermodynamic factors are discussed, as well as engine efficiency.
Technical Paper

Simulors, An Innovative Tool for Molds Development

1996-04-01
91A117
Mold designers and foundrymen spend a lot of time in developing molds without knowing exactly the phenomena which take place inside. Simulor, which has been used in an industrial environment for two years, offers the solution to make foundrymen understand what happens during the filling of the mold and the solidification of the part. Based on navier-stokes and heat transfer equations, simulor provides speed distribution and metal front evolution in the cavity and thermal map in the mold and the part. Some examples with different metals (cast iron, aluminum alloy) cast with various processes (sand or die casting, low pressure or gravity casting) will be given. This new tool will given foundrymen the opportunity to test the mold before having it machined and will also allow reduction in development delays.
Technical Paper

The Development of Plastic Lenses for Vehicle Headlamps

1996-04-01
91A111
The pending changes in European law enabling the use of plastic lenses on vehicle headlamps provide an opportunity for further advancement of vehicle styling, lighting performance and aerodynamic efficiency. Plastic lenses can also provide a useful weight saving and contribute to energy savings during the lifetime of the vehicle. This paper discusses the current requirements, technologies and solutions for plastic lenses, and indicates the way this advance can impact on the evolution of lighting products.
Technical Paper

Evaluation of Advanced Aluminum Alloys and Mmc Obtained By Means of a Spray Depositon Approach

1996-04-01
91A112
The paper review some recent efforts, made by the aluminum industry, towards the development of new advanced alloys for aerospace applications; unconventional production technologies and MMC occupy an outstanding position in this context. Raid solidification processes are currently used for obtaining advanced alloys and, among them, the powder metallurgy route is one of the most commonly applied, since it has reached a considerable level of maturity. Experimental results of PM materials are shown and discussed in order to appreciate the potentialities of this class of materials and some recent further progress is shown: the spray deposition approach (osprey process). After having described the main features of the osprey process, some results obtained at the Department of Aerospace Engineering of Pisa about the development of high strength Al-alloy and MMC obtained by means of the osprey process are shown.
Technical Paper

Toothed Couplings for Diesel Engines: An Example of Steel Substitution With Fiber Reinforced Plastics

1996-04-01
91A100
The replacement with plastic of an important component, formerly in steel, in the timing drive of a heavily duty diesel engine has been studied and realized. The substituted part is the toothed coupling connecting the injection pump to the timing drive. Torque that stresses the coupling has been measured with laboratory tests. The tooth stresses have been calculated with FEM analysis. Finally, fatigue tests have been carried out directly on the engine at different loadings. The test results are consistent with the predicted behavior of this component.
Technical Paper

Actuation and Fastening With Shape Memory Alloys in the Automotive Industry

1996-04-01
91A103
As a result of a phase transformation, shape memory alloys can change their shape when the temperature changes. This unusual effect can be utilized in actuation and fastening components for automotive applications. Springs made from Ni-Ti shape memory alloys change their rate in a predetermined temperature range due to a significant change in the elastic modules of the material. They can be used as sensor-actuators in pressures control valves or oil cooler by-pass valves in automatic transmissions or to compensate for oil viscosity changes in shock absorbers or thermal expansion of dissimilar materials in gear boxes. If the recovery is constrained, i.e., shape memory element is physically prevented from returning into its original shape, a potentially high stress is generated. This effect is used in fastener rings. Fasteners made from Ni-Ti alloys provide high reliability and easy installation for braid terminations, locating of shaft mounted components, connectors and hose clamps.
Technical Paper

Ceramic Coating for Aluminum Engine and Components

1996-04-01
91A105
The trend toward lighter vehicles for improved performance has recently introduced the use of aluminum and plastic materials for vehicle bodies and drive trains. In particular, the aluminum alloy block foar engine application is certain to reappear. The soft aluminum cylinder liner will require additional treatment before acceptance. Three possible approaches appear to solve the aluminum cylinder liner dilemma. These approaches are: 1) use of high silicon aluminum such as the 390 aluminum; 2) insert or cast steel liners into the aluminum engine block; and 3) ceramic coat the low cost standard aluminum engine block. Each has known advantages and disadvantages. It is the purpose of this paper to present the merits of option 3, the ceramic coated aluminum cylinder bore, from the standpoint of low weight, cost, and tribological effectiveness. The advantages of approaches 1) and 2) are obvious. High temperature after treatment of the ceramic engine components is not required.
Technical Paper

Practical Applications of Composite Exotic Hybrids and Their Structural Use in Vehicles

1996-04-01
91A098
An overview of high strength thermoset and thermoplastic composites will provide a basis of comparison with exotic hybrid composites. A specific theoretical application for a very high strength unibody application will be presented and test results evaluated. A critical overview of immediate applications will be presented and evaluated. In conclusion, it will be suggested that a uniform standard of performance be established for the practical application's requirements for these materials
Technical Paper

Optimisation of Diesel Engines Converted to High Compression Spark Ignition (SI) Natural Gas Operation

1988-03-01
871149
There is a strong interest around the world in natural gas as an alternative fuel. This paper is concerned with the option of converting diesel engines to spark ignition operation. Although this may appear to be an outrageous thermodynamic action, it is preferable to using natural gas in a low compression gasoline engine conversion. An investigation is described in which engine maps were produced for a 5.6 litre direct injection diesel engine converted to CNG. The diesel operating characteristics have been compared with those of the spark ignition conversion at compression ratios of 18:1 (the original diesel value), 15:1 and 13:1. Detailed data are presented for the 15:1 compression ratio. These test results are supplemented by results for other diesel conversions. The use of these engines in bus fleet operations is also discussed.
Technical Paper

Trends and Forecasts for Turbocharging

1988-03-01
871147
Predictable and unpredictable forces will change the direction of the charge-air systems industry. The driver of diesel engine development will be the stringent emissions regulations of the 1990s. The drivers in the gasoline engine market will be improved fuel economy, performance, durability and emissions. Forces will also influence the charge-air marketplace, including changes in emission standards, national fiscal policies, political issues, fuel prices, alternate fuels and consumer tastes. The world community mandate for engines that are clean, quiet, durable and fuel efficient will be satisfied, increasingly, by first-tier component suppliers developing integrated systems solutions.
Technical Paper

U.S. and California Vehicle Emissions Control Programs Effectiveness and Application of Experience

1988-03-01
871148
Many areas of the world are in various stages of development which frequently includes a rapid increase in the motor vehicle population. As a result, some areas are beginning to show the effect of increased motor vehicle use on air pollution. The vehicle's contribution to California's air pollution has long been recognized and studied, and measures have been implemented to reduce emissions from motor vehicles. The history of light duty vehicle emission control in the South Coast Air Basin of California is reviewed. Emission reductions achieved, current levels, projected future emissions and the need for further emissions reductions from light duty vehicles are discussed. For other areas of the world where motor vehicles contribute to air pollution, suggestions are made which can improve the effectiveness of emission control efforts; which should be consistent with political and economic realities, and efforts to achieve international harmonization of standards.
Technical Paper

Performance and Exhaust Emission in Spark Ignition Engine Fueled with Methanol-Butane Mixture

1988-03-01
871165
To improve the cold startability of methanol, methanol-butane mixed fuel was experimented. Engine performance and exhaust emissions are obtained with methanol-butane mixed fuel. These characteristics are compared with those of methanol and gasoline. The mixing ratios of methanol and butane are 50:50 (M50), 80:20 (M80), and 90:10 (M90) based on the calorific value. As a result, M90 produces more power than gasoline and more or less than methanol depending on the engine speed and the excess air ratio. Brake horse power of M90 is higher than that of gasoline by 5 - 10 %, and brake specific fuel consumption is smaller than that of gasoline by 17 % to the maximum based on the calorific value. NOx emission concentrations for M90 are lower than those for gasoline and higher than those for methanol because of the effect of butane, CO emission concentrations are somewhat lower than those for methanol and gasoline.
Technical Paper

Engine Control System for Lean Combustion

1988-03-01
871171
In order to achieve lean burn engine control system, it is necessary to develop high accuracy air fuel ratio control technology including transient driving condition and lean burn limit expansion technology. This paper describes the following. 1 The characteristics of the transient response of the fuel supply are clarified when various kinds of air flow measuring methods and fuel injection methods are used. 2 To achieve stable combustion in lean mixture, fine fuel droplet mixture, whose diameter is less than 40 μm, needs to be supplied.
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