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Standard

WIRING COMPONENT DESIGN GUIDELINES
2009-07-10
HISTORICAL
USCAR12-3
This document gives general guidelines to be used during the connector design stage. Various guidelines may not apply in all situations. Therefore, sound engineering judgment must be used in their application. Consider these guidelines as the basis for connector and wiring DFMEA’s. Items in this document are grouped by DFMEA functional requirements. Groups are as follows: A Electrical Continuity B Electrical Isolation/Sealing C Device Assembly D Harness Assembly E Vehicle Assembly F Materials G Serviceability H Environmental Requirements I High Voltage (≥ 60V) Application Requirements
Standard

Torque-Tension Testing and Evaluation of Fastener Finishes
1998-12-30
HISTORICAL
USCAR11
This standard provides a test method for determining the torque-tension relationship of a fastener finish as applied to a surrogate screw for the purpose of measuring the frictional characteristic of the fastener finish. The results obtained by this test shall be used as a process control attribute of the fastener finish and shall not be utilized for specific applications.
Standard

TORQUE-TENSION TESTING AND EVALUATION OF FASTENER FINISHES
2020-11-19
CURRENT
USCAR11-2
This standard provides a test method for determining the torque-tension relationship of a fastener finish as applied to a surrogate screw for the purpose of measuring the frictional characteristic of the fastener finish. The results obtained by this test shall be used as a process control attribute of the fastener finish and shall not be utilized for specific applications.
Standard

TEST PROCEDURES FOR EVALUATING BOLT-LOAD RETENTION OF MAGNESIUM ALLOYS
2020-11-19
CURRENT
USCAR35-1
A bolt-load retention (BLR) test is a practical test to determine the bolt load of a fastener joint with time and at given temperatures. There are three types of BLR tests described in this standard, namely general-purpose test, design-purpose test, and screening material test. A general-purpose BLR test may be used for screening materials, while a design-purpose BLR test is usually used to verify the BLR behavior of a specific joint. The screening material test is an example of the general-purpose test for typical automotive applications.
Standard

TEST PROCEDURES FOR EVALUATING BOLT-LOAD RETENTION OF MAGNESIUM ALLOYS
2007-10-08
HISTORICAL
USCAR35
A bolt-load retention (BLR) test is a practical test to determine the bolt load of a fastener joint with time and at given temperatures. There are three types of BLR tests described in this standard, namely general-purpose test, design-purpose test, and screening material test. A general-purpose BLR test may be used for screening materials, while a design-purpose BLR test is usually used to verify the BLR behavior of a specific joint. The screening material test is an example of the general-purpose test for typical automotive applications.
Standard

TEST FOR EVALUATING THE TORQUE-TENSION RELATIONSHIP OF BOTH EXTERNAL AND INTERNAL METRIC THREADED FASTENERS
2007-04-05
HISTORICAL
USCAR10-2
This standard provides a test method for determining the torque-tension relationship of both external and internal metric threaded fasteners for the purpose of measuring the frictional characteristics of the threaded fasteners. The results obtained by this test are relevant to the test conditions only and should not be utilized for specific applications.
Standard

TEST FOR EVALUATING THE TORQUE-TENSION RELATIONSHIP OF BOTH EXTERNAL AND INTERNAL METRIC THREADED FASTENERS
2004-05-14
HISTORICAL
USCAR10-1
This standard provides a test method for determining the torque-tension relationship of both external and internal metric threaded fasteners for the purpose of measuring the frictional characteristics of the threaded fasteners. The results obtained by this test are relevant to the test conditions only and should not be utilized for specific applications.
Standard

TEST FOR EVALUATING THE TORQUE-TENSION RELATIONSHIP OF BOTH EXTERNAL AND INTERNAL METRIC THREADED FASTENERS
1998-12-30
HISTORICAL
USCAR10
This standard provides a test method for determining the torque-tension relationship of both external and internal metric threaded fasteners for the purpose of measuring the frictional characteristics of the threaded fasteners. The results obtained by this test are relevant to the test conditions only and should not be utilized for specific applications.
Standard

Shipping Caps, Torque Caps, and Body Plugs Ergonomic Design Criteria
2015-03-30
CURRENT
USCAR43
This document describes the design and assembly force guidelines for conventional shipping caps, torque caps, and body plugs. All possible design and applications could not be anticipated in creating these guidelines. Where there are questions of adherence to this document, such as use of an “off-the-shelf” design, always consult the responsible Ergonomics Department.
Standard

STANDARD FOR TIRE TRACEABILITY CONTENT AND FORMAT FOR THE RADIO-FREQUENCY IDENTIFICATION (RFID) TAG AND ASSOCIATED TIRE DATA SET
2020-11-19
CURRENT
USCAR39-1
This standard describes a requirement for automotive tire traceability. It includes a definition of the RFID tag and the associated tire data set that can be accessed using the RFID tag as an identifier. The standard describes a unique identification and the associated data set for each tire produced by the tire fabricator. This data will either be provided or transmitted at the time of shipment to retailers, wholesalers or original equipment vehicle manufacturers. Tire identification code and data may be used for error proofing, determining the tire specifications or supporting any inquiries that occur for the duration of its automotive life.
Standard

ROAD VEHICLES – 60 V AND 600 V SINGLE CORE (ISO/METRIC) CABLES – DIMENSIONS, TEST METHODS AND REQUIREMENTS
2017-07-13
CURRENT
USCAR23-1
This International Standard specifies the dimensions, test methods, and requirements for single core 60 V cables intended for use in road vehicle applications where the nominal system voltage is ≤ (60 V DC or 25 V AC). It also specifies additional test methods and/or requirements for 600 V cables intended for use in road vehicle applications where the nominal system voltage is > (60 V DC or 25 V AC) to ≤ (600 V DC or 600 V AC). It also applies to individual cores in multi-core cables. See ISO 6722 for “Temperature Class Ratings”.
Standard

ROAD VEHICLES – 60 V AND 600 V SINGLE CORE (ISO/METRIC) CABLES – DIMENSIONS, TEST METHODS AND REQUIREMENTS
2002-09-09
HISTORICAL
USCAR23
This International Standard specifies the dimensions, test methods, and requirements for single core 60 V cables intended for use in road vehicle applications where the nominal system voltage is ≤ (60 V DC or 25 V AC). It also specifies additional test methods and/or requirements for 600 V cables intended for use in road vehicle applications where the nominal system voltage is > (60 V DC or 25 V AC) to ≤ (600 V DC or 600 V AC). It also applies to individual cores in multi-core cables. See ISO 6722 for “Temperature Class Ratings”.
Standard

Performance Specification for Ultrasonically Welded Wire/Cable Termination
2009-12-18
HISTORICAL
USCAR38
IMPORTANT NOTICE: In any intended vehicle application, if the products covered by this specification are, or may be, subjected to conditions beyond those described in this document, they must pass special tests simulating the actual conditions to be encountered before they can be considered acceptable for actual vehicle application. Products certified by their supplier as having passed specific applicable portions of this specification are not to be used in applications where conditions may exceed those for which the product has been satisfactorily tested. The Authorized Person is the final authority as to what tests are to be performed on his or her parts and for what purpose these tests are required. He or she is also the final authority for resolving any questions related to testing to this specification and to authorizing any deviations to the equipment or procedures contained in this specification.
Standard

PERFORMANCE SPECIFICATION FOR WELDED WIRE-TO-WIRE SPLICES
2018-06-14
CURRENT
USCAR45
SAE/USCAR-45 defines test methods and performance requirements for ultrasonically-welded wire-to-wire splices for automotive applications. Face-to-face, butt splice, and center strip configurations per Figure 1 can be tested. The tests defined in this specification subject samples on test to stresses that simulate a lifetime of exposure for a road vehicle. Stresses called out in this specification include thermal shock, temperature/humidity cycling and mechanical stress from different directions.
Standard

PERFORMANCE SPECIFICATION FOR ULTRASONICALLY WELDED WIRE TERMINATIONS
2016-04-05
HISTORICAL
USCAR38-1
This specification defines test methods and performance criteria for evaluating ultrasonically welded wire-to-terminal metallurgical bonds. The examples used are specific to the linear weld type of process equipment. USCAR-38 is not applicable for “Splice Welding”. The specification is applicable to wire-on-pad configurations with a typical weld shown in Figure 1. This test specification subjects parts under test to environmental exposures to simulate a lifetime of field exposure for a road vehicle. Exposures called-out in this specification include Thermal Shock, Temperature Humidity Cycling and mechanical abuse. This test specification is intended to evaluate the strength and performance of the interface between wires to an electrical terminal. Validation of the performance of the Terminal is a separate task and can be accomplished using a component validation test such as SAE/USCAR-2, which evaluates whether the entire connection system is acceptable.
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