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More than 200 tensile-shear resistance spot welded specimens were produced and tested to analyze the effect of spot weld spacing, weld size, sheet thickness, and adhesive on the ultimate strength of joints made from a mild hot dip galvannealed steel and an unexposed quality hot dip galvannealed 590 MPa minimum tensile strength dual phase steel (DP590). The geometric layout parameters were analyzed by a design of experiment (DOE) approach. The analysis showed that weld size is a primary factor affecting the strength of the joints for a given material. It was also determined that structural adhesive created a large relative strengthening for joints made from the mild steel. Interactions of the geometrical factors are also presented.

Single-plane balancing is a very well-understood process, whereby an imbalance vector is determined and then opposed by a similar vector of equal magnitude but 180° out of phase. This is used in many situations to improve machine performance, vibration, noise etc. However, there is inherent in this process a sensitivity to errors of measurement and correction, since a large imbalance vector and the equally large correction vector must be of exactly equal magnitude and exactly 180° apart for perfect balance. This paper examines the effect of errors in measurement of the initial imbalance and correction of it on the residual balance of automotive drivelines. In particular, it examines the effects of the errors present in a system whereby a system balance correction is made, on a driveline assembly, at discrete points around a given plane (at bolt locations). Errors occur in measurement of vibration, in calculating correction masses and in applying those correction masses.

Traditional methods used to produce a die set (from developing initial machining cutter paths through finalized die tryout to produce a part that meets design intent) begin with draw simulation and development. It is here, traditionally, that scientific evaluation of actual metal stretch and theoretical ideals end. In past programs, a designed part would be simulated for stretch and a development model created to include various die compensations (i.e. springback, overcrown, etc.) based on past experience for area and amount. At this point, the die is cut and undergoes a metamorphosis through die tryout to finally produce a quality part. This is currently an open loop system. This paper will focus on the differences in the predicted way the die should look and the actual outcome (after part buyoff).

A new family of automotive three-way conversion (TWC) catalyst technologies has been developed using a Precision Metal Addition (PMA) process. Precious metal (PGM) fixation onto the support occurs during the PMA step when the PGM is added to the slurry immediately prior to application to the monolith substrate. PMA slurries can be prepared with high precision and the slurry manufacturing process is greatly simplified. Further, it has been found that with the use of new generation washcoat (WC) materials, the same WC composition can be used for all three PGMs - Pt, Pd & Rh. Negative interactions between Pd and Rh in the same WC layer do not occur, providing advantages over older technologies. Thus, new WC compositions coupled with the PMA process offers precious metal flexibility. This FlexMetal family of catalyst technologies includes single layer Pd-only, Pd/Rh and Pt/Rh and dual layer bi-metal Pd/Rh and Pt/Rh and tri-metal Pt/Pd/Rh.

An early development vehicle experienced an unusually high rate of windshield breakage. Most breaks were identified as due to impact, but the severity of impact was low. It was reasoned that the windshield should possess a greater level of robustness to impact. Many theories were put forth to explain the breakage data. It was universally agreed that the unusual breakage rate could be due to only one condition, but its source was indefinite. The condition present must be tensile stress. One of three situations were considered regarding its source: 1) the tensile stress was present in the glass after manufacture due to improper annealing; 2) the installation of the windshield into the vehicle body put the glass into stress; 3) some combination of the other two sources. A gray-field polariscope was used to measure the stresses of the windshield from both the manufacturing process as well as the installation in the vehicle.

The automobile industry is seeing an increased need for the application of plastics and their derivatives in various forms such as fiber reinforced plastics, in the design and manufacture of various automotive structural components, to reduce weight, cost and improve fuel efficiency. A lot of effort is being directed at the development of structural plastics, to meet specific automotive requirements such as stiffness, safety, strength, durability and environmental standards and recyclability. This paper presents the concept of reinforcing large injection molded fiber reinforced body panels with structural uni-directional fibers (carbon, graphite, kevlar or fiber glass) wound in tension around the body panels by filament winding technique. Structural uni-directional fibers in tension wound around the fiber reinforced plastic inner body panels would place these body panels under compression.

Reductions of hardware costs as well as implementations of new innovative functions are the main drivers of today's automotive electronics. Indeed more and more resources are spent on adapting existing solutions to different environments. At the same time, due to the increasing number of networked components, a level of complexity has been reached which is difficult to handle using traditional development processes. The automotive industry addresses this problem through a paradigm shift from a hardware-, component-driven to a requirement- and function-driven development process, and a stringent standardization of infrastructure elements. One central standardization initiative is the AUTomotive Open System ARchitecture (AUTOSAR). AUTOSAR was founded in 2003 by major OEMs and Tier1 suppliers and now includes a large number of automotive, electronics, semiconductor, hard- and software companies.