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For many years, the use of in-mold fasteners has been avoided for various reasons including: not fully understanding the load cases in the part, the fear of quality issues occurring, the need for servicing, or the lack of understanding the complexity of all failure modes. The most common solution has been the use of secondary operations to provide attachments, such as, screws, metal clips, heat staking, sonic welding or other methods which are ultimately a waste in the process and an increase in manufacturing costs. The purpose of this paper is to take the reader through the design process followed to design an in-molded attachment clip on plastic parts. The paper explores the design process for in-molded attachment clips beginning with a design concept idea, followed by basic concept testing using a desktop 3D printer, optimizing the design with physical tests and CAE analysis, and finally producing high resolution 3D prototypes for validation and tuning.

The advent of turbochargers and the Eco-Boost technology at Ford in gasoline engines creates new challenges that need to be addressed with innovative designs. One of them is flow induced noise caused by airflow entering the turbocharger during off design operation. At certain vehicle operation conditions, the mass flow rate and pressure ratio are such that compressor wheel can generate a wide range of acoustic frequencies. Characterization of ‘whistles’ or pure tonal noises, ‘whoosh’ or broad band frequency noise caused by flow separation from the blade surfaces, and chirps, where the frequency increases or decreases with time are a few of the common error states. Understanding the fundamental mechanisms of such noise generation is necessary for developing effective countermeasures for the noise source generation. Computational Aero-Acoustic (CAA) analyses are performed to study the effects of inlet and outlet conditions to find the source of the noise.

Statistical Energy Analysis (SEA) is an established high-frequency analysis technique for generating acoustic and vibration response predictions in the automotive, aerospace, machinery, and ship industries. SEA offers unique NVH prediction and target-setting capabilities as a design tool at early stages of vehicle design where geometry is still undefined and evolving and no prototype hardware is available yet for testing. The exact frequencies at which SEA can be used effectively vary according to the size and the amount of damping in the vehicle subsystems; however, for automotive design the ability to predict acoustic and vibration responses due to both airborne and structure-borne sources has been established to frequencies of 500 Hz and above. This paper presents the background, historical use, and current industrial applications of structure-borne SEA. The history and motivation for the development of structure-borne SEA are discussed.

This paper describes a joint SAE automotive and aerospace Recommended Practice SAE J3168 now in development to standardize a process for Reliability Physics Analysis. This is a science-based approach to implement Physics-of-Failure research in conducting durability simulations in a Computer Aided Engineering Environment. It is used to calculate failure mechanism susceptibilities and estimate the likelihood of failure and the expected durability life of Electrical, Electronic and Electromechanical components and equipment, due to stresses such as mechanical shock, vibration, temperature cycling, etc. Reliability Physics Analysis is based on the material science principle of stress driven damage accumulation in materials. The process enables the identification of potential failure risks early in the design phase so that such risks can be designed out in order to efficiently design high reliable and robustness into electronic products.

An L16 orthogonal array parameter Design of Experiment (DOE) evaluated six design parameters of the mating thread interface between the exhaust manifold outlet flange and jointing stainless steel fastener. The objective of this study was to identify optimal parameters for the redesign the thread interface by ensuring 100% seating of the fastener into the manifold flange (here after referred to as stud seating). Since the current fastener and manifold outlet flange interface threads do not always achieve the design objectives, due in part to a form of abrasive wear, consideration was given to develop a testing strategy that would quantify the amount of remaining thread engagement for a given stud length. This testing strategy ensured that the control parameters considered in this experiment would reveal main effects and interactions between the stud and tapped hole threads thus providing the necessary parameters for the redesign on the joint threads.

Objective: This study analyzed available rear impact sled tests with Starcraft-type seats that use a diagonal belt behind the seatback. The study focused on neck responses for out-of-position (OOP) and in-position seated dummies. Methods: Thirteen rear sled tests were identified with out-of-position and in-position 5 th , 50 th and 95 th Hybrid III dummies in up to 47.6 mph rear delta Vs involving Starcraft-type seats. The tests were conducted at Ford, Exponent and CSE. Seven KARCO rear sled tests were found with in-position 5 th and 50 th Hybrid III dummies in 21.1-29.5 mph rear delta Vs involving Starcraft-type seats. In all of the in-position and one of the out-of-position series, comparable tests were run with production seats. Biomechanical responses of the dummies and test videos were analyzed.

The desire to move high-energy Pulsed Power systems from the laboratory to practical field systems requires the development of compact lightweight drivers. This paper concerns an effort to develop such a system based on a plastic laminate strip Blumlein as the final pulse shaping stage for a 600 kV, 50ns, 5-ohm driver. A lifetime and breakdown study conducted with small-area samples identified Kapton sheet impregnated with Propylene Carbonate as the best material combination of those evaluated. The program has successfully demonstrated techniques for folding large area systems into compact geometry's and vacuum impregnating the laminate in the folded systems. The major operational challenges encountered revolve around edge grading and low inductance, low impedance switching. The design iterations and lessons learned will be discussed. A multistage prototype testing program has demonstrated 600kV operation on a short 6ns line.

Corrugated-core sandwich structures with integrated acoustic resonator arrays have been of recent interest for launch vehicle noise control applications. Previous tests and analyses have demonstrated the ability of this concept to increase sound absorption and reduce sound transmission at low frequencies. However, commercial aircraft manufacturers often require fibrous or foam blanket treatments for broadband noise control and thermal insulation. Consequently, it is of interest to further explore the noise control benefit and trade-offs of structurally integrated resonators when combined with various degrees of blanket noise treatment in an aircraft-representative cylindrical fuselage system. In this study, numerical models were developed to predict the effect of broadband and multi-tone structurally integrated resonator arrays on the interior noise level of cylindrical vibroacoustic systems.

The modal frequencies of a structure often exhibit random variation. This variation may be an important factor affecting structural response. This paper summarizes the results of a combined experimental and analytical study that considers modal frequency randomness arising from boundary condition random variation. It is shown that a simple measure of boundary condition characteristics can be used in connection with a finite element based analysis to estimate random variation in modal frequencies. A comparison between the experiment and the analysis confirms the accuracy of the analytical technique.

This paper describes a program to develop a miniaturized chemical laboratory (μChemLab™). This system includes multiple analysis channels each with microfabricated sample collectors/concentrators, gas chromatographic separators, and chemically selective detectors based on an array of coated surface acoustic wave devices. This development effort is currently focused on fabricating small (palm-top computer sized), lightweight, and autonomous systems that provide rapid (1 min), sensitive (1-10 ppb), and selective detection of chemical warfare agents. The small size and low power of the μChemLab™ technology make it potentially useful for monitoring of compounds such as volatile organic compounds (VOCs), ammonia, and formaldehyde in space environments.

Advanced rechargeable lithium-ion batteries are presently being developed and commercialized worldwide for use in consumer electronics, military and space applications. The motivation behind these efforts involves, among other things, a favorable combination of energy and power density. For some of the applications the power sources may need to perform at a reasonable rate at subambient temperatures. Given the nature of the lithium-ion cell chemistry the low temperature performance of the cells may not be very good. At Sandia National Laboratories, we have used different electrochemical techniques such as impedance and charge/discharge at ambient and subambient temperatures to probe the various electrochemical processes that are occurring in Li-ion cells. The purpose of this study is to identify the component that reduces the cell performance at subambient temperatures.

A laboratory study was performed to assess the effectiveness of LNT+SCR systems for NOx control in lean exhaust. The effects of the catalyst system length and the spatial configuration of the LNT & SCR catalysts were evaluated for their effects on the NOx conversion, NH₃ yield, N₂O yield, and HC conversion. It was found that multi-zone catalyst architectures with four or eight alternating LNT and SCR catalyst zones had equivalent gross NOx conversion, lower NH₃ and N₂O yield, and significantly higher net conversion of NOx to N₂ than an all-LNT design or a standard LNT+SCR configuration, where all of the SCR volume is placed downstream of the LNT. The lower NH₃ emissions of the two multi-zone designs relative to the standard LNT+SCR design were attributed to the improved balance of NOx and NH₃ in the SCR zones.

Two tests of composite shells loaded under half-cosine impulsive loadings are discussed. One cylinder which included no other materials was modeled successfully such that calculated results matched test results out to late times. The other cylinder, which included an inner annulus of an elastomeric material, was less successfully modeled, even though the composite material was modeled similarly in both instances. A viscoelastic model and an elastic model were both used to model the elastomeric material, and the viscoelastic model produced significantly better results.

The rapidly increasing use of composites on commercial airplanes coupled with the potential for economic savings associated with their use in aircraft structures means that the demand for composite materials technology will continue to increase. Inspecting these composite structures is a critical element in assuring their continued airworthiness. The FAA's Airworthiness Assurance NDI Validation Center, in conjunction with the Commercial Aircraft Composite Repair Committee, is developing a set of composite reference standards to be used in NDT equipment calibration for accomplishment of damage assessment and post-repair inspection of all commercial aircraft composites. In this program, a series of NDI tests on a matrix of composite aircraft structures and prototype reference standards were completed in order to minimize the number of standards needed to carry out composite inspections on aircraft.

Free form fabrication, or rapid prototyping as it is commonly known, is the creation of a physical entity, directly from numerical description, using an additive process. The mathematical data used is typically in the form of a 3D CAD file, but it may also be obtained from a reverse engineering process. This paper presents a review of three of the leading FFF (free form fabrication) systems which are commercially available. Time constraints will allow us to describe only three of these products. Although this does not do justice to a technology where there are more than 30 different systems in various stages of development, these examples represent the vast majority of machines which are in the marketplace today.

Thermal batteries are normally constructed using pressed-powder anode, separator, and cathode pellets (discs). However, parts less than 0.010” thick are difficult to press from the starting powders. The use of plasma spraying to deposit thin pyrite films onto a stainless steel substrate was examined as an alternative to pressed-powder cathodes. The electrodes were tested under isothermal conditions and constant-current discharge over a temperature range of 400°C to 550°C using a standard LiSi anode and a separator based on the LiCIKCI eutectic. The plasma-sprayed cathodes were also evaluated in similar 5-cell thermal batteries. Cells and batteries using pressed-powder cathodes were tested under the same conditions for comparative purposes.

Silica aerogels have 1/3 the thermal conductivity of the best commercial composite insulations, or ~13 mW/m-K at 25 °C. However, aerogels are transparent in the near IR region of 4-7 μm, which is where the radiation peak from a thermal-battery stack occurs. Titania and carbon-black powders were examined as thermal opacifiers, to reduce radiation at temperatures between 300°C and 600°C, which spans the range of operating temperature for most thermal batteries. The effectiveness of the various opacifiers depended on the loading, with the best overall results being obtained using aerogels filled with carbon black. Fabrication and strength issues still remain, however.

Computer Aided Engineering (CAE) has become a vital tool for product development in automotive industry. Increasing computer models are developed to simulate vehicle crashworthiness, dynamic, and fuel efficiency. Before applying these models for product development, model validation needs to be conducted to assess the validity of the models. However, one of the key difficulties for model validation of dynamic systems is that most of the responses are functional responses, such as time history curves. This calls for the development of an objective metric which can evaluate the differences of both the time history and the key features, such as phase shift, magnitude, and slope between test and CAE curves. One of the promising metrics is Error Assessment of Response Time Histories (EARTH), which was recently developed. Three independent error measures that associated with physically meaningful characteristics (phase, magnitude, and slope) were proposed.

High concentrations of diesel fuel can accumulate in the engine oil, especially in vehicles equipped with diesel particle filters. Fuel dilution can decrease the viscosity of engine oil, reducing its film thickness. Higher concentrations of fuel are believed to accumulate in oil with biodiesel than with diesel fuel because biodiesel has a higher boiling temperature range, allowing it to persist in the sump. Numerous countries are taking actions to promote the use of biodiesel. The growing interest for biodiesel has been driven by a desire for energy independence (domestically produced), the increasing cost of petroleum-derived fuels, and an interest in reducing greenhouse gas emissions. Biodiesel can affect engine lubrication (through fuel dilution), as its physical and chemical properties are significantly different from those of petrodiesel. Many risks associated with excessive biodiesel dilution have been identified, yet its actual impact has not been well quantified.