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Nisshin Steel Co., Ltd. has developed a new process for the production of a “one-side aluminized steel sheet”. The process utilizes a double layer one-side “stop-off” coating to prevent the molten Al from adhering to the steel surface. The “Stop-off” coating is removed by simple mechanical brushing after hot dipping. The characteristics of this product by above mentioned process are: 1) The steel side was as clean as a conventional cold rolled surface and showed no trace of the “stop-off” layer. Thereby, phosphating and ED painting were performed. 2) In the salt spray test data was obtained from zinc and Al coated steel surfaces; the coatings on both surfaces being of equal thickness.

NEW WELDING processes are dropping costs while providing improvements in weld quality. This paper describes some of the more promising new developments in pressure and fusion welding and brazing. Included in the discussion are ultrasonic, high frequency resistance, foil seam, magnetic force, percussion, friction, and thermopressure welding and diffusion bonding. The description of adhesive bonding includes the development of glass or ceramic materials as structural adhesives.*

This specification covers the requirements for producing a zinc phosphate coating on ferrous alloys and the properties of the coating.

Interactions between a Zinc dialkyldithiophosphate (ZDP) and three different commercially available succinimide dispersants were observed through changes in solutions behavior, as determined by viscometry and Fourier Transform Infrared spectroscopy (FTIR), and four-ball tests. The viscometric response observed for two component blends of ZDP and succinimide dispersant in white oil changed as a function of the molar Zn to N ratio, indicative of specific interactions. The break in the viscometric response curve occurred at Zn:N=0.13 for all three succinimide dispersants. FTIR spectra of the same ZDP-dispersant blends were examined and similar Zn:N dependencies were observed. Four-ball tests measuring wear scar diameter, seizure load and weld load showed a dependence on the Zn to N ratio similar to that observed by viscometry. At very low Zn to N ratios wear and seizure load were decreased, while at higher ratios the seizure and weld loads were increased over that for ZDP alone.

HOT-DIP galvanized steel sheets have been increasingly used in the automotive industry. However, two major problems occur during spot-welding because of the presence of zinc: 1/ Welding parameters differ from those used for bare sheets 2/ Electrodes life span often decreases. Two products have been thoroughly tested: 1/ Usinor MONOGAL® sheet 2/ Two-sides hot-dip galvanized sheet with various zinc-coating thicknesses. Welding parameters have been optimized by the determination of weldability lobes. Both products present a wide range of intensities, provided that weld current and electrode force are increased. The effect of an enventual variation of zinc-coating thickness is negligible. Electrodes life satisfies the FORD 2000 spot welds acceptance test. At last, temperature measurements inside the electrodes have shown the interest in increasing the electrodes tip diameter.

The thermal deflection associated with the conventional die heat treating procedure usually requires extra die grinding process to fine-tune the die surface. Due to the size of the production die, the grinding is time consuming and is not cost effective. The goal of the study is to develop a new die heat treating process utilizing the flexible laser heat treatment, which could serve the same purpose as the conventional die heat treating and avoid the thermal deflection. The unique look of the developed zebra pattern laser heat treating process is defined as the Zebra Line. The heat-treating parameters and processes were developed and calibrated to produce the laser heat treating on laboratory size dies, which were subjected to the die wear test in the laboratory condition. The USS HDGI 980 XG3TM steel was selected to be carried out on the developmental dies in the cyclic bend die wear test due to its high strength and coating characteristic.

This specification covers the engineering requirements for electrodepositton of zinc and the properties of the deposit.

The Reflection Grating Spectrometer experiment (RGS) on the ESA corner stone X-Ray Multi-Mirror Mission (XMM) uses charge coupled devices (CCD) as detectors. Thermal requirements are the main driver for the layout of the detector housing. Parasitic heat inputs stem primarily from radiative coupling and from conduction over the structural support. Improvements in the design of the electro optical model (EOM) over the bread board model (BBM) resulted in a system that guarantees a CCD temperature of -130 °C at the end of the mission while not precluding the possibility to heat the detectors as high as +130°C which might be useful for annealing the CCDs.

The development of the XB-70 research aircraft produced advancements in many fields of technology. This paper covers a few of these advancements in the areas of materials, equipment, and manufacturing. These include honeycomb construction, PH 15-7 alloy steel, vacuum melted H-11 steel, equipment capable of withstanding high temperatures, chemical milling of many different alloys, miniaturized welding equipment, and exothermic brazing techniques.

THE X-ray spectrum readily adapts itself to problems in chemical analysis and crystal formation. It is effective on very minute particles which otherwise cannot be segregated. A permanent record is made, and the specimens may be used over and over again, as the X-ray is non-destructive. As a means of inspection, X-ray clearly shows the interior of objects such as weldings castings, forgings, cold-worked metals, and so on. Inhomogeneities that are very slight in width and a fraction of one per cent in thickness are seen easily on a radiograph. Defects thus found may be eliminated summarily by checking various steps in production.

This standard1 describes the chemical, mechanical, and dimensional requirements for a wide range of wrought copper and copper alloys used in the automotive and related industries.

Automotive structural components are exposed to high loads, impact situations and corrosion. In addition, there may be temperature excursions that introduce creep as well as reduced modulus (stiffness). These issues have limited the use of light metals in automotive structural applications primarily to aluminum alloys, and primarily to cast wheels and knuckles (only a few of which are forged), cast brake calipers, and cast control arms. This paper reports on research performed at Chongqing University, Chongqing China, under the auspices of General Motors engineering and directed by the first author, to develop a protocol that uses wrought magnesium in control arms. The goal was to produce a chassis part that could provide the same engineering function as current cast aluminum applications; and since magnesium is 33% less dense than aluminum, would be lighter.

In this paper, the mechanical properties, structural performance and mass saving potential of wrought magnesium alloys are compared to several major automotive materials: mild steel, advanced high-strength steel, cast and wrought aluminum, cast magnesium, plastics and fiber-reinforced composites. Manufacturing processes including welding and joining of magnesium extrusions and sheet products are critically reviewed. The current and potential applications of wrought magnesium alloys in automotive interior, body and chassis areas are discussed. Technical challenges and research opportunities for these applications are identified.

This standard1 describes the chemical, mechanical, and dimensional requirements for a wide range of wrought copper and copper alloys used in the automotive and related industries.