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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.

This study examined methods of machining a microsurface texture on the surface of the rolling elements of a toroidal continuously variable transmission (CVT) for improving the traction coefficient. The microsurface texture of the toroidal surfaces consists of tiny circumferential grooves (referred to here as micro grooves) and a mirror-like surface finish similar to the rolling surface of bearings. Hard turning with a cubic boron nitride (cBN) cutting tool, grinding with a cBN wheel and micro forming were applied to machine the micro grooves. The results made clear the practical potential of each method. A micro forming device was also developed for use in actual production. A mirror-like surface finish and micro crowning of the convex portions of the microsurface texture were simultaneously executed by superfinishing them with a fine-grained elastic superfinishing stone.

Recently tailored blank sheets are widely and very often applied to car body's panels in order to reduce weight and number of automobile parts. The tailored blank sheets are produced by welding more than two metal sheets. The gap between edges of blank sheets before laser welding should be controlled for obtaining good quality tailored blank sheets. Therefore control of gap within 0.1mm between batting two blank sheets for production is one of main subjects for producing tailored blank sheets. This report presents not only a new mechanism on gap control but also a development of Finite Element Method (FEM) analysis for prediction of gap. The new mechanism has been applied successfully to produce good quality tailored blank sheets. The gap prediction simulation can reduce the time for gap control apparatus design.

One important development area for obtaining better fuel economy is to reduce mechanical friction losses in engine components. The valvetrain is a significant source of mechanical friction loss in an automobile engine, especially at low speeds where fuel economy is most important. This paper describes the potential use of diamond-like carbon (DLC) coatings at the cam/follower interface in a bucket-type valvetrain. Using a pin-on-disk tester, a motored valvetrain friction apparatus and a bench test rig, the frictional performance of DLC coatings was tested. Experimental data indicate that under a lubricated condition, DLC coatings produced by a plasma CVD (chemical vapor deposition) technique did not show a sufficient effect on reducing friction (only a 20-25% reduction) contrary to our expectations. DLC coatings prepared by arc-ion plating and containing less hydrogen showed superior frictional performance compared with CVD-DLC coatings under a lubricated condition.

An investigation was made of techniques for reducing the friction of lightweighted direct-acting valve train systems. The techniques examined included improving the cam/follower surface finish and reducing the valve spring load. The characteristics of each approach and the valve train friction reduction obtained with each one were clarified by experimentation and analysis. As a result, the friction reduction techniques analyzed in this work reduce the friction level of a direct-acting valve train by approximately 40% in comparison with the previous valve train. These techniques have been applied for the direct-acting valve train system of new-generation, lightweight, 3-liter V6 Nissan engine.

Down-gauging outer panels is an effective method for reducing the weight of an automobile body. We have succeeded in narrowing the thickness of outer panels by using rib-shaped plastic reinforcement. The plastic reinforcement consists of unhardened resin and an adhesive sheet, and it conforms well to the curved panel surface. In the body paint oven, it is hardened on the outer panels and forms a rib-shaped structure. This paper describes the composition of the resin material, the manufacturing process and the strength and rigidity of outer panels made with the rib-shaped reinforcement. It also discusses the weight reduction effect achieved by applying these panels to the doors of a production vehicle.

This paper describes the plastic body panels developed for the Nissan Be-1 which was released and put on sale in Japan in January 1987. The panels include four body parts: left and right front fenders, front apron and rear apron. They are made of a thermoplastic resin and are produced by injection molding. The top paint coat can be sprayed on all four panels simultaneously with other steel body panels. The panels provide a high-quality appearance that is in no way inferior to the paint quality of steel panels. This is true during initial use as well as over long periods of time. Besides providing weight reductions, they also deliver improved resistance to impacts. CAE process was applied to develop these panels and proved to be quite effective.

THIS PAPER presents an advanced heads-up display which has been newly developed for use in 88 Nissan Silvia model. The HUD consists of a projector with a newly developed high brightness VFD and light-selective film used as a combiner which is coated on the windshield. This combination provides good display legibility even under bright sunlight. The display shows the vehicle speed in a three-digit reading at distance of more than one meter from the driver's eyes. The windshield-coated combiner conforms to U.S. safety standards concerning light transmittance, abrasion and other performance requirements. Experimental data are also presented which substantiate the HUD's high legibility and confirm its effect in enhancing the driver's attention toward the road ahead

The current spray painting system is hardly considered that the thickness is controlled enough, because the temperature greatly influence on the viscosity of paint. We noticed the problem and detected the temperature at a nozzle of a spray unit. We tried that the paint flow is controlled to get stable thickness more accurately by the temperature feedback system. We also tried to develop the new programming method of robots. This new offline programming system provided us an ideal positions and orientations of the spray gun mounted on a robot wrist, after several simulation in the CAD system. We checked and debugged the office taught date with a trial robot in a trial area, and then loaded down with the date to a target robot. We eventually provided a better production technology with the paintflow control system together with the new CAD based offline programming system.

A new transparent type electrochromic device (ECD) has been developed. It consists of two electrochromic thin films facing each other, one of “prussian blue” (PB) and the other of tungsten trioxide (WO3). PB exhibits a high intensity of coloration and is blue in the oxidized state and transparent in the reduced state. By electrodeposition, the PB layer can be formed on large substrates at low cost. This ECD has been applied to large, curved automotive glass. It reversibly turns from dark blue to transparent at low operating voltage and maintains the same intensity of coloration without the aid of an external power supply. Compared with photochromic glass, it achieves a greater color change in a shorter time and its light absorption can be changed at will. It shields passengers from the discomfort of glare and heat flow through glass.

This paper deals with the development of plastics recycling technology, which is one key to resolving environmental and natural resource problems and encouraging recycling activities. Bumpers are among the heaviest plastic auto parts, so the technology for recycling bumpers is strongly required. Paint remaining on bumpers causes the strength of the recycled material to decline and degrades its surface quality. Therefore, unless the paint is removed, it is impossible to use recycled material to manufacture new bumpers. This hampers recycling efforts and results in low-value recycled material. Consequently, it is essential to develop a simple paint removing without chemical substances for practical plastics recycling at low cost. Two topics are discussed in this paper. The first concerns the mechanism of paint removal and the development of a technique for utilizing that mechanism.

Technologies applied to the Nissan Tino Hybrid, marketed in March 2000, in Japan, are expected to evolve into the core powertrain technologies of the future, for the following technical advantages inherent to hybrid EVs: 1 Regeneration of deceleration energy 2 Motor driven propulsion at low speed, combined with power-assisted operation in the mid- and high-load ranges. It is expected that a number of models will be introduced to the market in the future, which pursue these advantages in various forms, resulting in HEV technologies to accelerate the use of electric power for the vehicle. Fuel cell vehicles will be included in this future scenario. In this paper, our view on the future HEV technologies will be described. In addition, the latest technologies applied to the Nissan Tino Hybrid will be introduced.

This paper describes the development of the drive motor adopted on the newly developed 2013 Model Year (MY) electric vehicle (EV). Based on the 2011MY EV that was specifically designed and engineered for mass-production, the 2013MY powertrain integrates the electric motor, inverter and charging system into one unit in order to achieve downsizing and weight saving, unlike previous 2011 model which had these components segregated. In general, integration of all components into one unit causes deterioration of the noise and vibration performance of vehicles due to an increase in weight and the number of resonance parts. In order to overcome such problems associated with this integration, each component in the 2013 model has been optimized to reduce noise and vibration resulting in high degree of vehicle quietness.

Nissan’s variable compression turbo (VC-Turbo) engine has a multilink mechanism that continuously adjusts the top and bottom dead centers of the piston to change the compression ratio and achieve both fuel economy and high power performance. Increasing the exhaust gas recirculation (EGR) rate is an effective way to further reduce the fuel consumption, although this increases the exhaust gas condensation in the cylinder bores, causing a more corrosive environment. When the EGR rate is increased in a VC-Turbo engine, the combined effect of piston sliding and exhaust gas condensation at the top dead center accelerates the corrosive wear of the thermal spray coating. Stainless steel coating is used to improve the corrosion resistance, but the adhesion strength between the coating and the cylinder bores is reduced.