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A NEW TEST is described for studying the oxidation stability of automatic transmission fluids (ATF). The test shows an excellent correlation with transmission oxidation tests and points out the importance of time as a variable in such studies. Carefully controlled automobile dynamometer tests have been used to study the shear stability of ATF's. Data are presented showing a comparison of driving conditions, transmissions, and V.I. improvers on shear stability. Results are related to the 50-hr Hydra-Matic durability test. The poor reproducibility of rubber swell measurements on commercial transmission seals is due largely to differences in the rubber compounds. A great improvement in the reproducibility may be made by taking into account the specific gravity of the rubber sample.*

“Trapless” Trap, which makes possible the effective collecting of particulates in diesel exhaust gas and their simultaneous combustion has been developed by use of a ceramic foam in combination with catalysts containing copper salt. From a TEM photograph, it was observed that the particulate was rapidly oxidized by mobile copper ion, showing worm-eaten like spots. Screening of various base metal salts by TGA presented CUCl2-KCl-NH4VO3 and CuCl2-KCl-(NH4)6Mo7O24 as very active catalysts for diesel particulate oxidation. They had thermal stability up to 900°C when they were supported on titania. The results obtained by measuring the back pressure using 1.8L diesel engine suggest the above trap to be a self-cleaning trapless trap.

This paper presents, chemistry, test data and processing procedures on a non toxic and environmentally friendly chrome-free conversion coating alternative with the same level of adhesion and secondary corrosion resistance as that found in chrome containing conversion coating systems. Test data from military and independent sources will be presented on secondary coating adhesion, electrical conductivity, filiform and neutral salt-spray corrosion resistance as compared to chromate based systems .on magnesium, aluminum and zinc and their respective alloys. The European “RoSH” initiative will not allow for the presence of any hexavalent chromium on imported electrical components as of July first of 2006. Trivalent chromium based systems generate hexavalent chromium due to the oxidation of the trivalent chromium and as such will not be allowed.

Vehicle dynamics is a discipline of mechanical engineering that benefited of significant improvements thanks to the progress of computational engineering. Vehicle dynamics engineers are using CAE for the development of a vehicle with MBS and FEA. The concurrent use of these two technologies is a standard in the automotive industry. However the current simulation process is not fully efficient because local geometrical and material nonlinearities are not accurately modeled in classical MBS software. This paper introduces a methodology for vehicle dynamics simulation integrating MBS capabilities in one single nonlinear FEA environment enabling an accurate modeling of nonlinearity in vehicles.

MONOGAL is a coated steel developped to improve the corrosion resistance of exposed automotive body applications. Its process os based on the brittleness of the η zinc coating in a range of temperatures below the melting point of the zinc. MONOGAL is produced on a hot dip galvanizing line; at the exit of the pot the free zinc is brushed off the light side of the differentially coated sheet. Side 1 of MONOGAL presents a very thin and continuous layer of iron-zinc diffusion alloy with no free zinc. Side 2 is a standard G90 or G60 zinc coating. The iron-zinc alloy layer has excellent anti-galling properties which improve the formability of MONOGAL over two side hot dip galvanized steel with the same r value. MONOGAL also shows good weldability, paintability and corrosion resistance.

In recent years there has been increasing interest in quantifying the emissions from aircraft in order to generate inventories of emissions for climate models, technology and scenario studies, and inventories of emissions for airline fleets typically presented in environmental reports. The preferred method for calculating aircraft engine emissions of NOx, HC, and CO is the proprietary “P3T3” method. This method relies on proprietary airplane and engine performance models along with proprietary engine emissions characterizations. In response and in order to provide a transparent method for calculating aircraft engine emissions non proprietary fuel flow based methods 1,2,3 have been developed. This paper presents derivation, updates, and clarifications of the fuel flow method methodology known as “Fuel Flow Method 2”.

Carbon and rephosphorized pre-strained sheet steels for cold drawing forming operations were studied and the tensile, high cycle fatigue and fatigue crack propagation properties were determined. The fatigue limit was found to be higher for 20% than for 1% pre-strained condition. Threshold stress intensity factors (▵Ků) of 5.29 MPa. m1/2 for rephosphorized steel and 7.07 MPa. m1/2 for carbon steel. Critical crack lenghts were calculated by ▵Ků and fatigue limit data using the Lukas-Klesnil short-crack criterion. Through fractographic analysis it was possible to determine the general behavior of tested materials near threshold.

“DELRIN” is a new thermoplastic which offers high strength, excellent thermal stability, good fatigue life, low creep, and excellent solvent resistance. This paper describes the physical and chemical properties of the material, and the range of possible uses. The material is easily fabricated into complex shapes by standard injection-molding techniques. Also, it can be easily joined to itself or to other materials. The authors think that the material offers advantages over metals in its good fric-tional properties, abrasion resistance, and corrosion resistance.

A wide body aircraft carries almost a half–ton of water and ice between the cabin and skin of the aircraft. The water can get on wires and connectors, which can cause electrical problems, cause corrosion and rust, and, eventually, “rain in the plane”. The speaker is the CEO of CTT Systems that has developed a system that solves the condensation by using dry air. The speaker will discuss how condensation can be prevented and how airlines can also save maintenance costs in the process. This topic is relevant for the attendees at the Aerospace Expo, as they are decision makers who need to be aware of this issue. It is also important for the MRO shows as the attendees are on the front lines of dealing with this problem.

The objective of the development of the aerodynamic drag predictive tool CDaero was for use as a module for the Automobile Design Support System (AutoDSS). CDaero is an empirically based drag coefficient predictive tool based initially on the MIRA (Motor Industry Research Association) algorithm. The development philosophy was to be able to predict the aerodynamic drag coefficient of an automobile with knowledge of the features of the surface geometry control curves. These are the curves that control the 3-dimensional geometry as seen in the profile, plan and front and rear views. CDaero has been developed in a computing environment using the equation solver TKSolver™. Fifty-one input feature values are first determined from the automobile geometry and then entered into the program. CDaero models the drag coefficient with thirteen different components covering the basic body, as well as additional components such as the wheels, mud flaps, etc.

In today’s Automotive world, there is NO need to advocate “Light weighting”. Government policies for carbon footprint reduction combined with high safety standards are driving OEMs to adopt advanced manufacturing technologies. Steel hot forming is selected as most preferred way to reduce weight as it is easy to adopt and commercially known. It had many advantages compare to conventional cold stamping of standard and high tensile steel. The process consists of heating blank to nearly 1000 °C and quenching it in tool to for martensitic structure. Higher strength up to 2000 MPa can be achieved by this process. There are many examples where part weight is reduced by 15 to 20 % by this method. But Steel hot forming has limitation as specific density of steel is still high. Thus, there is limitation to its weight reduction capability. For further reduction, OEMs have started exploring Aluminium hot forming.

Buick engineers are well pleased with their '69 Chassis. Benefits of a unique front suspension camber curve are documented. The effects of various suspension parameters on ride and handling are explained. These were varied independently of one another in the course of evaluating over 30 suspension configurations.

With the advent of low evaporative emission requirements there has been the rapid adoption of multilayer extrusion technology into the production of Fuel and Vapour tubing used on Fuel systems on automobiles. Multilayer extrusion technology enables a manufacturer of Fuel and Vapour tubing to simultaneously co-extrude dissimilar thermoplastic materials in tubular form. This allows the manufacturer to combine expensive and brittle high performance evaporative emission ‘barrier’ polymers with lower cost engineering polymers. However, it is a well-known characteristic of these multilayer tube constructions that the joints between them and connector ‘barbs’ have lower joint integrity. Joint integrity is most often quantified by ‘Pull-off’ and leakage tests. Recent developments in LEV-II requirements for 2004 and beyond indicate that joint integrity will become a focus area for study and improvement.

3-D Flow separations such as those that occur on the rear end of a vehicle have an impact on wall pressure distribution, hence on aerodynamic forces. The identification of these phenomena can be made through the analysis of skin friction patterns, which consist of the “footprints” of flow separations. These can be determined from qualitative and quantitative data obtained from near-wall PIV measurements. The wake flow of different configurations of a simplified 1/4 scale car model are analyzed. The influence of the slant angle and the Reynolds number on 3-D separated flow patterns and their induced pressure distribution is addressed, based on near-wall PIV, standard PIV and wall pressure measurements. This enables to understand how a topological change (the size or shape of a separation pattern) modifies the associated pressure distribution (therefore the drag coefficient). Finally, insights into instantaneous topology identification are presented.

THE DEVELOPMENT of new polymers offering properties and new combinations of desirable characteristics, coupled with advances in manufacturing techniques, has expanded the plastics horizon. This paper describes some of these new materials and a few of their many possible applications in the automotive industry. The author emphasizes that greater use of plastics in the automotive field depends to a great degree on the imagination and ability applied in creating new products. Design features most overcome the fundamental limitations of the new materials. The basic weaknesses of plastics are listed. Production techniques will affect the future expansion of the industry. Three methods show particular promise: blow molding, fluidized polymer deposition, and potting compounds.*

THE usefulness of planetary gear trains and the engineering techniques necessary for optimum design are discussed in this paper. A simple method for calculating planetary gear ratios is described which can be used to determine quickly the potential usefulness of any planetary configurations. The author lists criteria which help to evaluate the potential of a planetary gear train schematic from the standpoints of gear noise and structural viewpoint. Detailed design of individual members include spacing of the pinions, mounting considerations, thrust direction, lubrication, and stress evaluation.

THIS PAPER reviews VTOL problems, indicating probable ways toward optimization of whole lifting and propelling system. Also discussed are the power and thrust requirements for optimum cruise and vertical take-offs and landings for propeller-driven and jet-propelled aircraft. Three speed ranges offer the most promise for VTOL aircraft, if thrust requirements for cruise and take-off are to match. The ranges are centered around Mach numbers of 0.65, 0.8, and 2.0+. There is a possibility of overcoming the high thrust needed for hovering by use of bypass augmentation, special hovering jets, or favorable ground effects, the author reports.

THE optimum mode of control for an aircraft engine is dependent on both the configuration of the engine and its application. Each engine application requires several detail modes of control, one for each definable regime of operation of the engine. Discussions of control requirements can be simplified by classifying these regimes by objectives: physical limiting, thrust, and transient control. The turbojet engine is the basis for the discussion in this paper. Acceptable modes of control can often be selected by inspection of the engine and its application. Selection of an “optimum” control mode requires investigation of the operation of the engine and weapons system at every stage of its use. The selection of a “mode” of control requires a compromise between performance and other design factors. The need for simplicity and accuracy must be balanced against the stability requirements. The availability and flexibility of control components may limit the modes of control considered.

STRUCTURAL MATERIALS for Mach 3 jet transports pose difficult problems for the design engineer. Reasons for this problem are the incomplete information available on the many possible metals and the diversity of critical properties that are added by supersonic requirements. The material properties discussed in this paper include tensile strength, resistance to crack propagation, ease of fabrication, weldability, and thermal expansion. Cost factors are also considered. The structural configuration of the wing and fuselage is an example of the complexity of the material selection problem. The wing may be rigidity-critical, and the fuselage strength-critical; each requires diferent material properties to solve the problem.*

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.*