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The wax has been developed that is able to protect vehicle bodies from corrosion for extended periods. Vehicle bodies, composed mainly of steel components, are prone to corrosion, in particular side sills and various flanges. These sections are generally coated with wax to protect them from water, primary corrosion-promoting factor, enabling manufacturers to offer extended warranties against corrosion perforation in their catalogs. However, while corrosion prevention systems using conventional waxes contribute significantly to increased corrosion prevention, they result in increased costs, for example for dedicated wax coating lines in production lines, and require specialized lines tailored to specific vehicle bodies. Areas such as side sills and various flanges require careful attention to, and particularly high standards of, corrosion prevention. Particular attention to coating required in these areas tends to increase volume of coating material employed.

This paper presents an overview of the progression of the contemplated candidate volumes for the Lunar Lander since the beginning of the Vision for Space Exploration in 2004. These sets of data encompass the 2005 Exploration Systems Architecture Study (ESAS), the 2006 Request for Information on the Constellation Lunar Lander, the 2007 Lander Design Analysis Cycle −1 (LDAC-1) and the 2008 Lunar Lander Development Study (LLDS). This data derives from Northrop Grumman Corporation analyses and design research. A key focus of this investigation is how well the lunar lander supports crew productivity.

A long-duration lunar outpost will rely entirely upon imported or preserved foods to sustain the crew during early Lunar missions. Fresh, perishable foods (e.g. salad crops) would be consumed by the crew soon after delivery by the re-supply missions, and can provide a supplement to the diet rich in antioxidants (bioprotectants) that would serve as a countermeasure to radiation exposure. Although controlled environment research has been carried out on the growth of salad crops under a range of environmental conditions, there has been no demonstration of sustainable production in a flight-like system under conditions that might be encountered in space. Several fundamental challenges that must be overcome in order to achieve sustained salad crop production under the power, volume and mass constraints of early Lunar outposts include; growing multiple species, sustaining productivity through multiple plantings, and minimizing time for crew operations.

Multiple field trials and nearly a decade of laboratory studies have demonstrated that shear stable multigrade hydraulic fluids improve fuel economy. These studies have determined that fuel efficiency is dependent upon temperature, fluid viscosity and shear stability. This paper presents a viscosity classification system proposed by the National Fluid Power Association (NFPA) Fluids Technical Committee. This system is analogous to the SAE J300 viscosity classification system for engine oils. The letter “L” is used in place of “W” as the designation for the low temperature grade. Under this new classification system, NFPA 32L-68 fluids will provide the low temperature viscosity properties of an ISO VG 32 hydraulic fluid and the high temperature viscosity properties of an ISO VG 68. In addition, fluids that meet the requirements of the proposed NFPA Energy Efficient classification system increase fuel economy and productivity while reducing CO2 emissions.

Many engineers have been working to reduce brake noise in many ways for a long time. So far, a progress has been made in preventing and predicting brake noise. Nevertheless, there are some discrepancies of brake noise generation propensity between testing for the prototype and the production. As known in general, the reason for this unpredicted brake noise occurrence in production is partly due to the variation of the resonant frequency, material and the other unpredictable or unmanageable variations of the components in a brake system. In this paper, effects of chemical components and casting process of gray iron brake disc on its resonant frequency variation have been studied. Especially this paper is focused on the variation in material aspects and manufacturing parameters during disc casting in usual production condition. And their effects are investigated by the variation of out-of-plane modal resonant frequency.

The effectiveness of serial link articulated robots in aerospace drilling and fastening is largely limited by positional accuracy. Unguided production robotic systems are practically limited to +/-0.5mm, whereas the majority of aerospace applications call for tolerances in the +/-0.25mm range. The precision with which holes are placed on an aircraft structure is affected by two main criteria; the volumetric accuracy of the positioner, and how the system is affected when an external load is applied. Production use and testing of off-the-shelf robots has highlighted the major contributor to reduced stiffness and accuracy as being error ahead of the joint position feedback such as backlash and belt stretch. These factors affect the omni-directional repeatability, thus limiting accuracy, and also contribute to deflection of the tool point when process forces are applied.

Patents granted recently to Mr. Rode have changed the industry capability to adjust and verify wheel-end bearings on trucks. Until now it was believed1 that there was nothing available to confirm or verify the most desirable settings of preload on these bearings. The new, breakthrough invention is a tool and spindle-locking nut that permit quick and accurate wheel bearing adjustment by utilizing direct reading force measurement. Bearings can be set to either SAE recommended preloads or specific endplay settings. The author has been working on bearing adjustment methods for industrial applications for over forty years, and considers these inventions to be his most important breakthrough for solving this elusive bearing adjustment problem. Consistent wheel bearing preload adjustment was not possible before, even though it was widely known to achieve the best wheel performance as noted in SAE specification J2535 and re-affirmed in 2006 by the SAE Truck and Bus Wheel Subcommittee.

Model-Based Design with production code generation has been extensively utilized throughout the automotive software engineering community because of its ability to address complexity, productivity, and quality challenges. With new applications such as lane departure warning or electromechanical steering, engineers have begun to consider Model-Based Design to develop embedded software for applications that need to comply with safety standards such as IEC 61508. For in-vehicle applications, IEC 61508 is often considered state-of-the-art or generally accepted rules of technology (GART) for development of high-integrity software [6, 11]. In order to demonstrate standards compliance, the objectives and recommendations outlined in IEC 61508-3 [8] must be mapped onto processes and tools for Model-Based Design. This paper discusses a verification and validation workflow for developing in-vehicle software components which need to comply with IEC 61508-3 using Model-Based Design.

Due to the conventional autoclaving of pre-impregnated materials causes high costs in the production of carbon fibre structures, new injection methods have become more and more relevant. The research project “CFK-Tex” focuses on the automated handling and processing of preforms out of dry carbon fibre textiles. Regarding the advantages in quality improvement and process time, an automation of all process steps is getting enforced. The major challenge, in addition to the difficult handling-properties of the materials and high quality demands, is the enormous variety of outline variants caused by small production quantities but many different textile cuts per part. In the first step the requirements of an automated system are exactly analyzed considering the specific material properties as well as process and product based characteristics.

Cyber-physical systems consisting of networks of interacting systems are often developed by distributed teams in a production environment. Processes, tools and work products supporting development of cyber-physical systems are continuously evolving through the different design phases. A growing trend to manage the development process has been the use of model-based development approaches. However, these approaches primarily use behavioral models to represent complex systems, rendering them inadequate to address collaborative and non-functional program requirements. This paper discusses an architecture-driven process that can address the challenges posed during the development of cyber-physical systems. Two key enabling technologies – the SAE AADL (Architecture Analysis and Design Language) and the IME (Integrated Modeling Environment) are leveraged in this process.

The post-flame oxidation of unburned hydrocarbons released from the ring-pack crevice was investigated for a small, air-cooled, spark-ignition utility engine. Spark timing sweeps were performed at 50, 75 and 100% load and speeds of 1800, 2400 and 3060 RPM while operating at a 12:1 air-fuel ratio, which is typical for these engines. A global HC consumption rate (GCR) was introduced based on the temporal profile of the mass released from the ring pack; the mass release after CA90 and up to the point where the remainder of the ring pack HC mass is equal to the exhaust HC level was taken as the mass oxidized, and a rate was defined based on this mass and the corresponding crank angle period over which this took place. For all conditions tested, the GCR varied with the spark timing; advanced spark timing gave higher GCR.

This paper presents the results of investigations that were carried out on a single-cylinder spray-guided direct injection engine. The effects of injection pressures of up to 1000 bar on combustion and emissions at the stability limit of stratified load are presented. It is known that at low engine speeds, problems in mixture preparation occur due to insufficient in-cylinder motion at higher loads in stratified charge operation. Additionally, adverse effects appear at high engine speeds due to limited time for vaporization and mixture formation. Therefore, investigations at various engine speeds ranging from 2000 to 4000 rpm were performed. As a baseline, a production multihole injector is compared with an injector that has been specially adapted for higher injection pressures.

Fuel wall impingement commonly occurs in small-bore diesel engines. Particularly during engine starting, when wall temperatures are low, the evaporation rate of fuel film remaining from previous cycles plays a significant role in the autoignition process that is not fully understood. Pre-injection chemiluminescence (PIC), resulting from low-temperature oxidation of evaporating fuel film and residual gases, was measured over 3200 μsec intervals at the end of the compression strokes, but prior to fuel injection during a series of starting sequences in an optical diesel engine. These experiments were conducted to determine the effect of this parameter on combustion phasing and were conducted at initial engine temperatures of 30, 40, 50 and 60°C, at swirl ratios of 2.0 and 4.5 at 1000 RPM. PIC was determined to increase and be highly correlated with combustion phasing during initial cycles of the starting sequence.

Biodistillate transportation fuels include biodiesel (produced via transesterification of animal fats and vegetable oils) and renewable diesel (produced via catalytic hydroprocessing of the same feedstocks). Production and use of biodistillates are increasing dramatically, both in the U.S. and globally. This paper describes the policy drivers prompting growth of biodistillate fuels in the U.S., Europe, and selected other countries. Trends in fuel production volumes and feedstocks supplies are presented for these fuels. Current feedstocks are dominated by soybean oil in the U.S. and rapeseed oil in Europe. However, there is much interest in developing alternative, non-edible feedstocks such as jatropha and microalgae. Currently, biodiesel is the dominant biodistillate in use, though interest in renewable diesel is increasing. This paper describes different conversion processes used to manufacture these fuels, and discusses the pros and cons of each.

Boeing has contracts for military application of twin engine airplanes generically identified in this paper as the MX airplane. Unlike previous derivatives, the MX airplanes are produced with a streamlined manufacturing process to improve cost and schedule performance. The final assembly of each MX airplane includes a series of integration tests, called factory functional tests (FFTs), which are modified from those of typical commercial versions and verify correctness of equipment installation and basic functionalities. Two airplanes have been through the production line resulting in a number of FFT lessons learned. Addressed are the power distribution lessons learned: 1) the expanded coverage of the basic automated power-on generation system test, 2) the need for a manual wire continuity test, 3) salient features of the power distribution tests, and 4) keys to make first pass power distribution test smooth and successful.

In present GDI engines, multiple injection strategies are often employed for engine cold start mixture formation. In the future, these strategies may also be used to control the combustion process, and to prevent misfiring or high emission levels. While the processes occurring during individual injections of GDI injectors have been investigated by a number of researchers, this paper concentrates on the interactions of multiple injection events. Even though multiple injection strategies are already applied in most GDI engines, the impact of the first injection event on the second injection event has not been analyzed in detail yet. Different optical measurement techniques are used in order to investigate the interaction of the two closely timed injection events, as well as the effect of dwell time and the in-cylinder conditions. The injector investigated is a GDI piezo injector with an outwardly opening needle.

In a previous paper [ 1 ], the authors have proposed a cost effective air hybrid concept based on a proprietary intake system and cam profile switching (CPS) system [ 2 ]. It was shown through engine simulations that the pneumatic hybrid operation could be achieved with about 15% regenerative efficiency. The proposed air hybrid operation can be achieved with proven technologies and engine components and hence it represents a cost-effective, reliable and quick deployable solution for low carbon vehicles. In this work, a four-cylinder 2 litre diesel engine has been modelled to operate on refined air hybrid engine configurations and the braking and motoring performance of each configuration have been studied. Both air hybrid systems can be constructed with production technologies and incur minimum changes to the existing engine design.

A new liquid surface conditioner has been developed to improve phosphate coating quality and enable a low-temperature phosphating system designed to reduce CO₂ emissions during the pretreatment processes of automobile production. Phosphate film is formed by a phosphating treatment that provides corrosion resistance for the steel plates that make up auto bodies. In the vehicle body, pocket-shaped structures such as side sills and wheel arches are likely to collect muddy water and form rust. Regarding anticorrosion quality assurance, particular attention must be paid to these pocket structures, in which phosphating solution flows slowly, and a lower solution-volume-to-surface-area ratio contributes less to the phosphating reaction. For this reason, with the conventional liquid surface conditioner, a low-temperature phosphating system cannot coat substrate surfaces sufficiently, which would result in lower corrosion resistance.

The continued need of vehicle weight reduction provides impetus for research into the development of novel automotive casting alloys and their processing technologies. Where possible, ferrous components are being replaced by aluminum (Al) and magnesium (Mg) alloy counterparts. This transition, however, requires a systematic optimization of the alloys and their manufacturing processes to enable production of defect-free castings. In this context, prevention of hot tears remains a challenge for Al and Mg alloy thin-wall castings. Hot tears form in semi-solid alloy subjected to localized tensile stress. Classical methods of stress measurement present numerous experimental limitations. In this research, neutron diffraction (ND) was used as a novel tool to obtain stress maps of castings and to quantify the effect of two processes used to eliminate hot tears in permanent mold castings: 1) increasing of the mold temperature during casting of Mg alloys, and 2) grain refinement of Al alloys.

Computed Tomography (CT) is a well established method for non-destructive reconstruction of an object's interior structures. It is especially well suited for use with e.g. light metal alloys, injection molded plastic components or composite materials. The CT volume data can either be evaluated manually or automatically through the use of image processing software. Recently helical CT has become available for use in industrial quality testing of light alloy cast parts. This paper discusses the use of helical CT as an additional tool for inline inspection in a production environment.