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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.

Auto manufacturers have known and surveys confirm that consumers require short payback periods (2-4 years) for investments in fuel economy. Using societal discount rates, engineering-economic generally find substantial potential to increase fuel economy, cost-effectively. This phenomenon, often referred to as the ?energy paradox?, has been observed in nearly all consumers? choices of energy-using durable goods. Loss aversion, perhaps the most well established theory of behavioral economics, provides a compelling explanation. Engineering economic analyses generally overlook the fact that consumers? investments in fuel economy are not sure things but rather risky bets. Future energy prices, real world on-road fuel economy, and many other factors are uncertain. Loss aversion describes a fundamental human tendency to exaggerate the potential for loss relative to gain when faced with a risky bet. It provides a sufficient explanation for consumers?

Moir� method is useful to measure the shape and the whole-field distributions of displacement and strain of structures. There are many kinds of moir� methods such as geometric moir� method, sampling moir� method, Fourier transform moir� method, moir� interferometry, shadow moir� method and moir� topography. Grating method analyzing directly deformation of a grating without any moir� fringe pattern is considered as an extended technique of moire method. Phase analysis of the moire fringe patterns and the grating patterns provides accurate measurements of shapes or displacement and strain distributions. Some applications of these moir� methods and grating methods to dynamic shape and strain distribution measurements of a rotating tire, sub-millimeter displacement measurements from long distance for landslide prediction, real-time shape measurements with micro-meter order accuracy, etc. are shown. Presenter Yoshiharu Morimoto, Moire Institute Inc.

Nissan Motor Company has recently released the �Nissan Green Program 2016� which is a six-year action plan embodying the company�s environmental philosophy: Symbiosis of People, Vehicles and Nature. One of the key activities of this Program is the successful penetration of Zero-Emission Vehicles into the market which includes electric vehicle (EV) cumulative sales of 1.5M units with our Alliance partner Renault, introduction of a fuel cell electric vehicle (FCEV) into the market, taking a global leadership in supplying batteries for electric drive and creating zero-emission societies. This presentation will highlight some of these key activities. Presenter Kev Adjemian, Nissan Technical Center NA

Learn how the U.S. Department of Energy's Clean Cities Program can help with the deployment of alternative fuel and advanced technology school buses. Presenter Mark S. Smith, US Department of Energy

Propane autogas, the world?s third most-used engine fuel, powers vehicles, transit buses, and now school buses. Blue Bird has recently launched the Next Generation Vision type C school bus, powered by a ROUSH CleanTech liquid propane autogas fuel system and a Ford 6.8L V10 engine. The bus reduces operating costs by up to 40%, greenhouse gas emissions by up to 24%, and maintains the factory horsepower, torque, and towing capacity ratings. Learn about how school districts are saving over $.30 / mile using this clean, domestically-produced fuel. Presenter Brian Carney, Roush CleanTech.

The System Architecture Virtual Integration (SAVI) program is a collaboration of industry, government, and academic organizations within the Aerospace Vehicle System Institute (AVSI) with the goal of structuring a new integration process that relies on a single-truth architectural framework. The SAVI approach of Integrate, then Build provides a modern distributed development environment which arrests the propagation of requirements errors through the development life cycle. It does so by capturing design assumptions and shared properties of the system design in an authoritative, annotated architectural model. This reference model provides a common, analyzable framework for confirming that system requirements remain complete, consistent, and correct at all levels of system decomposition. Core concepts of SAVI include extensive use of model-based system engineering tools and use of a single-truth reference architectural model.

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.

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.

The OBD approval process can be a frustrating time for both manufacturer and ARB staff. For manufacturers, a long approval process can sometimes mean accepting deficiencies prematurely in exchange for an approval. For ARB staff, they are inundated with highly technical information which they must review, garner understanding of and then apply their experience to evaluate it for compliance. OBD approval anxiety can be minimized, if not avoided, when manufacturers understand ARB�s expectations. This presentation will take you through some unwritten rules and common pitfalls which can impede the approval process, thus providing a guideline to a less painful and more efficient certification document review and approval. Presenter Mark Frank, Winterpark Engineering Llc

This session covers topics regarding new CI and SI engines and components. This includes analytical, experimental, and computational studies covering hardware development as well as design and analysis techniques. Presenter Joshua Styron, Ford Motor Co.

As a result of recommendation from the Augustine Panel, the direction for Human Space Flight has been altered from the original plan referred to as Constellation. NASA's Human Exploration Framework Team (HEFT) proposes the use of a Shuttle Derived Heavy Lift Launch Vehicle (SDLV) and an Orion derived spacecraft (salvaged from Constellation) to support a new flexible direction for space exploration. The SDLV must be developed within an environment of a constrained budget and a preferred fast development schedule. Thus, it has been proposed to utilize existing assets from the Shuttle Program to speed development at a lower cost. These existing assets should not only include structures such as external tanks or solid rockets, but also the Flight Software which has traditionally been a ?long pole? in new development efforts. The avionics and software for the Space Shuttle was primarily developed in the 70's and considered state of the art for that time.

Hybrid technology has the potential to enable dramatic reductions in greenhouse gases (GHG), such as the California goal of reducing GHG by 80 percent from 1990 levels by 2050. As a result it is expected that hybrid systems will occupy a growing proportion of the market. However, introducing a hybrid system in a vehicle may adversely affect the performance of the engine OBD system in monitoring malfunctions impacting pollutant emissions. For example, a hybrid system that reduces time of the engine in idle or deceleration overrun conditions could make a well-performing engine OBD system noncompliant, by reducing in-use frequency of some OBD monitors below acceptable levels. In this presentation, Ricardo will present a process for evaluating the impact that a hybrid system which has been optimised to minimise GHG emission over a specified drive-cycle will have on the effectiveness of engine OBD monitors.

Meet the engineers shaping the world of mobility and driving the future of engineering.

Alyson Lyon, Executive Leadership Coach, explains what stress is, and how to handle personally and professionally. SAE Members can view the full version by logging into the Member Connection. Not a Member? Join us today at sae.org/join.

Alyson Lyon, executive leadership coach, discusses the value of effective and efficient communication. SAE Members can view the full version by logging into the Member Connection. Not a Member? Join us today at sae.org/join.

Students share how SAE Membership has opened doors for their careers, provided educational opportunities and hands-on experiences that has helped them to become a better engineer.