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The 12 papers in this techncial paper collection represent research in the areas of welding, riveting, joining, and fastening for automotive applications. Papers focus on the recent advances in the process optimization, analytical solution, numerical modeling, response evaluation as well as static and dynamic testing of traditional resistance spot welds, gas metal arc welds, friction stir spot welds, laser welds, rivets, mounts, adhesives, and fasteners.

"Spotlight on Design" features video interviews and case study segments, focusing on the latest technology breakthroughs. Viewers are virtually taken to labs and research centers to learn how design engineers are enhancing product performance/reliability, reducing cost, improving quality, safety or environmental impact, and achieving regulatory compliance. Fuel efficiency, or simply put, how to get more mileage out of the same amount of fuel has become one of the main goals to be achieved by new automotive technologies in the future, thanks in part to new government regulations. In the episode "Fuel Efficiency: Racing toward CAFE 2025" (21:24) AVL engineers show simulation and testing being used to design more fuel efficient vehicles, including the equipment that actually analyzes fuel economy.

"Spotlight on Design: Insight" features an in-depth look at the latest technology breakthroughs impacting mobility. Viewers are virtually taken to labs and research centers to learn how design engineers are enhancing product performance/reliability, reducing cost, improving quality, safety or environmental impact, and achieving regulatory compliance. As global concerns about the negative consequences of greenhouse gases on the environment increase, regulatory agencies around the world are taking serious steps to address the issue of tailpipe emissions In the episode "Fuel Efficiency: Fuel Economy Testing" (12:01), engineers at the EPA’s National Vehicle and Fuel Emissions Laboratory demonstrate how different vehicles are tested for emissions, and AVL’s technical team shows how accurate tailpipe emissions can be measured and reported.

SAE 2011 High Efficiency IC Engines Symposium - Session 3 - Advanced Diesel Engine Technologies Presenter Andrew Brown, Delphi Corp.

Nissan has released our original HEV system in Japan on November 2010, and will release it in US market on March 2011. The 1 motor 2 clutch parallel type using conventional 7 speed automatic transmission has been employed without torque converter and with a manganese cathode and laminated type Li-ion Battery. This system is well recognized its higher efficiency but lower weight and cost, however, has never realized due to technical difficulties of smoothness. At this session, performance achievements and hinged breakthrough technologies will be presented. Presenter Tetsuya Takahashi, Nissan Motor Co., Ltd.

Hybrid systems have been available for several years now, and offer customers a decrease in fuel consumption and CO2 emissions at an incremental price. Hybrids, in some cases, have offered improved other customer benefits such as reduced noise, vibration and harshness or better acceleration and the satisfaction of increased societal benefit. Sometimes the vehicle utility is compromised by the volume dedicated to energy storage systems. Several hybrid architecture arrangements exist in the market, and offer various levels of hybrid feature. But considering acquisition cost and operating expense, most hybrid vehicles have not offered a direct total cost advantage when compared to non-hybrids. GM's new e-Assist system is highly integrated with the engine and transmission functionality, and takes advantage of the highest value fuel economy enablers available with light electrification.

Main topics are the development and the build-up of an 18ton hybrid truck with a parallel hybrid drivetrain. With this truck it is possible to drive up to 3 kilometers in the pure electric driving mode. Presenter Andreas Eglseer, Engineering Center Steyr GmbH & Co. KG

Vehicle electrification is shaping the future of automotive mobility in terms of automotive power and propulsion. The market for New Energy Vehicles (HEV/PHEV/REEV/EV) as well as clean vehicle technologies is expected to grow steadily driven by government regulations mandating increased fuel economy and lower emissions. The fastest growth in this market will be in Asia Pacific, most notably China. The Chinese government has made its intentions clear on how important it considers the development and consumer purchase of hybrid and electric vehicles. The mandate is that by year 2012, vehicle manufacturers produce at least 500,000 units (or 5%) per year of their total output as hybrid and/or electric. All Chinese vehicle manufacturers must have at least one HEV or EV model in the market by the same year. Thus far China has invested over US$3.5 billion to stimulate the production of NEVs and the necessary infrastructure to support them.

Toyota is committed to the development of advanced powertrains to help address concerns with future oil supplies, the impacts of increased carbon dioxide emissions, and air pollution. Towards that end Toyota is planning to bring to market in 2012 a plug-in hybrid vehicle, a short range electric vehicle, a long range electric vehicle and in the 2015 timeframe hydrogen powered fuel cell vehicle. This presentation will focus on our electric vehicle plans and the challenges with bringing electric vehicle to the market. From the 2010 Alt Fuels Study, Toyota has identified that two key barriers for EV adoption are the times to charge the vehicle, and electricity cost. The study finds that the current infrastructure could be sufficient for most driving needs but EV drivers will still need to alter their driving habits slightly.

Research in plug in vehicles (PHEV and BEV) has of course been ongoing for decades, however now that these vehicles are finally being produced for a mass market an intense focus over the last few years has been given to proper evaluation techniques and standard information to effectively convey efficiency information to potential consumers. The first challenge is the development of suitable test procedures. Thanks to many contributions from SAE members, these test procedures have been developed for PHEVs (SAE J1711 now available) and are under development for BEVs (SAE J1634 available later this year). A bigger challenge, however, is taking the outputs of these test results and dealing with the issue of off-board electrical energy consumption in the context of decades-long consumer understanding of MPG as the chief figure of merit for vehicle efficiency.

One of the major trends in the last decade has been the increasing hybridization in the vehicle population. The degree of hybridization varies from mild to strong including those capable of limited, all electric range. Some experts predict that hybridization will spread to 100% of vehicles in the next decade. In addition, the recent introduction of plug-in hybrid electric vehicles has added a significant new dimension to the hybridization scene. This talk will focus on the global trends in hybrid sales, including plug-in hybrids, and will try to identify the various mechanisms, whether legislation or incentives, which are driving this increase in sales. Data will be gathered from various countries in the world including China, Europe, Japan and the United States. The potential for different mechanisms in play in the developed world compared to the developing world will be examined.

Toyota is researching and developing several advanced vehicle powertrain technologies that increase fuel efficiency and decrease the environmental impact of consumer transportation. This presentation will describe the Toyota Plug-In Hybrid (PHV) architecture, its major components, the Toyota PHV Demonstration program, and the benefits of the Toyota approach to Plug-In hybrids. The current Toyota PHV features all electric driving for approximately 13 miles, while maintaining the fuel economy of Prius even when the vehicle is in hybrid mode. The vehicle that will be available in 2012 will also be affordable, allowing many customers to enjoy the benefits of electric drive. Presenter Avernethy Francisco, Toyota Motor Engineering & Manufacturing

Powertrain Systems development is facing unprecedented challenges driven by the convergence of many factors: increasing government regulations for tailpipe emissions, diagnostics and fuel economy, increased competition, shorter development cycles, and tighter program budgets. Using telematics and information technology to automate the evaluation of a system�s robustness enables engineers to focus their time on problem areas during their normal development process and launch with quality. This presentation will use real world examples to detail how this methodology was jointly applied by Control-Tec and Ford Motor Company to identify and improve the system performance of Ford�s Air-Fuel Imbalance Monitor before production. Presenter Bill Leisenring, Control-Tec LLC

Up to now, the reliability achieved by COTS components was largely sufficient for avionics, in terms of failure rate as well as time to failure. With the implementation of new and more integrated technologies (90 nm node, 65 nm and below), the question has arisen of the impact of the new technologies on reliability. It has been stated that the lifetime of these new technologies might decrease. The drift is expected to be technology dependent: integration, technology node, materials, elementary structure choices and process pay a key role. Figures have been published, which gives smaller lifetime than the 30 years generally required for avionics. This would of course impact not only the reliability, but also the maintenance of COTS-based avionics. Hence a new policy should be defined for the whole COTS supply chain. Faced with these impending risks, different methodologies have been developed.

This article characterizes the special features of drilling of CFRP/Titanium and -Aluminium stacks. Simplified theoretic models will show how CFRP/Titanium stacks should be machined without scratches and burn marks contacting carbon. Low axial forces and smart chip removal technology are the main characteristics of the drilling tool technology, optimized to reach H8 quality in one shot operation. Presenter Peter Mueller-Hummel, Cutting Tools Inc.

High Speed Machining of CFRP Parts Investigation of the influence of new geometries, cutting datas and coolant capabilities on the surface finish of CFRP parts. State of the art: Different CFRP grades and machining conditions make geometry adjustments to the tool necessary. Mechanical failures through machining operations can be avoided in most of the cases. New unidirectional CFRP grades and dry machining processes again lead to machining problems. This study investigates new geometries to avoid heat damage with dry maching and air coolant in case of unidirectional CFRP. With help of a thermo camera and the surface investigation with a scanning electron microscope, heat damage can be analysed and therefore new geometries can be developed and tested. Target is to develop a new multi purpose CFRP geometry to meet the requirements of the future. The reduction of different geometries used leads to major cost savings. Presenter Ingo von Puttkamer, Guhring oHG

In a variety of industries there is a growing need to manufacture high quality carbon fibre epoxy matrix composite structures at greater production rates and lower costs than has historically been the case. This has developed into a desire for the automation of the manufacture of components, and in particular the lay-up phase, with Automated Tape Laying (ATL) and Fibre Placement (AFP) the most popular choices. When used for large primary structures there are such potential gains to be had that both techniques have seen rapid implementation into manufacturing environments. But significant concerns remain and these have limited their wider adoption into secondary structure manufacturing, where manual forming of woven broadgoods is dominant. As a result the manufacture of secondary structures is generally explored for costs reduction through drape simulation and lower cost materials.

Zero-dimensional, one-dimensional, and quasi-dimensional models for simulation of SI and CI engines with respect to: engine breathing and boosting; SI combustion and emissions; CI combustion and emissions; fundamentals of engine thermodynamics; thermal management; mechanical and lubrication systems; system level models for controls; system level models for vehicle fuel economy and emissions predictions. Presenter Fabio Bozza, Universita di Napoli

Engine Boosting Systems. Presenter Andrew Williams, Loughborough Univ.

Exhaust Emission Control: DPF Systems. Presenter Shingo Iwasaki, NGK Insulators, Ltd.