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The U.S. Department of Energy (DOE) and the U.S. automotive industry are collaborating on research and development of advanced compression ignition direct injection (CIDI) engine technology and polymer electrolyte membrane (PEM) fuel cells for automotive applications. Under the auspices of the Partnership for a New Generation of Vehicles (PNGV), the partners are developing technologies to power an automobile that can achieve up to 80 miles per gallon (mpg), while meeting customer needs and all safety and emissions requirements. Research on enabling technologies for CIDI engines is focusing on advanced emissions control to meet the proposed stringent Environmental Protection Agency emissions standards for oxides of nitrogen (NOx) and particulate matter (PM) in 2004, while retaining the high efficiency and other traditional advantages of CIDI engines.

There is an ongoing interest in identifying new biodegradable hydraulic fluid compositions that may be used as alternatives to mineral oil in many hydraulic applications such as mobile off-highway equipment. To date, many basestocks have been proposed including: vegetable oils, polyol esters, diesters, synthetic hydrocarbons and others. One basestock is gaining interest as alternative, biodegradable, fire-resistant hydraulic fluid; anhydrous poly(alkylene glycol) (PAG) fluids. However, the use of these fluids is not new; they are simply being rediscovered. The objective of this paper is to provide an overview of the discovery and development of anhydrous PAGs as hydraulic fluids. This discussion will include: an overview of PAG chemistry, properties and hydraulic pump performance.

There is an ongoing interest in biodegradable hydraulic fluids. Biodegradable fluids are often considered to include only vegetable oils, polyol esters and diester base stocks. However, other fluid base stocks including highly refined mineral oils, poly(alpha olefins) and fire-resistant fluids such as water-glycol hydraulic fluids are also biodegradable fluid alternatives. This paper will provide an overview of the international literature on biodegradable fluids, various international testing protocol, fluid base stocks, effect of oxidative stability, material compatibility and pump performance.

Development of reliable magnesium (Mg) to steel joining methods is one of the critical issues in broader applications of Mg in automotive body construction. Ultrasonic spot welding (USW) has been demonstrated successfully to join Mg to steel and to achieve strong joints. In this study, corrosion test of ultrasonic spot welds between 1.6 mm thick Mg AZ31B-H24 and 0.8 mm thick galvanized mild steel, without and with adhesive, was conducted. Adhesive used was a one-component, heat-cured epoxy material, and was applied between overlapped sheets before USW. Corrosion test was conducted with an automotive cyclic corrosion test, which includes cyclic exposures of dipping in the 0.5% sodium chloride (NaCl) bath, a constant humidity environment, and a drying period. Lap shear strength of the joints decreased with the cycles of corrosion exposure. Good joint strengths were retained at the end of 30-cycle test.

The aerodynamics of the STOL aircraft can experience significant changes in proximity to the ground. A review of the existing data base and methodologies has been made and the results of that review are presented in this paper. The existing data show that in ground proximity the STOL aircraft will generally experience a reduction in the lift component regardless of the lifting configuration. Those configurations with integrated power and lift systems will have an additional effect of ground induced aerodynamic changes. This paper will discuss the existing data base and the deficiencies of that data base.

Reported tensile and fatigue properties of die cast AZ91D and AM60B magnesium alloys indicate that those values depend on the size and shape of the test samples and their global porosities. This paper reviews the mechanical properties reported in the open literature for these die cast alloys and indicates that section thickness and global porosity are inadequate for predicting the tensile and fatigue properties of die cast AZ91D and AM60B magnesium alloys.

This paper provides a review of the fatigue properties reported in the open literature for die cast magnesium-based alloys. Recently developed fatigue data, in the form of stress versus number of cycles to failure for bending fatigue (R=-1), are presented for die cast AM60B and AZ91D alloy specimens with thicknesses between 1 and 10 mm. The effects of specimen thickness and macrostructural features, such as porosity distributions and surface features (parting line and ejection pin marks), on the fatigue data are discussed.

The purpose of this paper is to survey the adverse environmental impacts resulting from motor vehicles, to review technologies developed to address these problems, and to summarize the current status of pollution control programs around the world.

There are numerous fluid-related performance concerns when hydraulic fluids are being qualified for use. These concerns are especially important when non-mineral oil derived hydraulic fluids are being qualified for use in unusual and critical applications. In this paper, a number of performance-related fluid deficiencies that may be encountered in use will be described.

Cavitation erosion is one of the most important causes of loss of hydraulic pump efficiency, wear and even failure. Although cavitation process is often understood, there is typically little understanding of the joint role of the hydraulic fluid, which is a component of the system, and the operation of the hydraulic pump. In this paper, an overview is provided that describes the fluid properties that most impact on cavitation damage, the cavitation process within the pump and components and the use of computer simulation to prove improved designs that minimize hydraulic cavitation when various types of fluids are used.

Cavitation is the dynamic process of gas cavity growth and collapse in a liquid. These cavities are due to the presence of dissolved gases or volatile liquids and they are formed at the point where the pressure is less than the saturation pressure of the gas (gaseous cavitation) or vapor pressure (vaporous cavitation). In this paper, various hydraulic system design factors and fluid properties affecting the cavitation process, and bubble collapse mechanisms will be discussed. In-situ generation of cavitation, examination of the cavitation process in model hydraulic systems, material effects and test methods will be reviewed.

The efforts of the ISO “Test Variability Task Force” have been aimed at improving the understanding and at reducing brake dynamometer test variability during performance testing. In addition, dynamometer test results have been compared and correlated to vehicle testing. Even though there is already a vast amount of anecdotal evidence confirming the fact that different procedures generate different friction coefficients on the same brake corner, the availability of supporting data to the industry has been elusive up to this point. To overcome this issue, this paper focuses on assessing friction levels, friction coefficient sensitivity, and repeatability under ECE, GB, ISO, JASO, and SAE laboratory friction evaluation tests.

Die cast AZ91D and AM60 magnesium alloy components are finding increasing usage in automotive applications. Both hot and cold chamber die cast components of these alloys generally exhibit several common microstructural features, including “skin”, porosity banding, and porosity distributed about the component centerline. Methods for quantitatively characterizing these microstructural features are described and representative values for skin thicknesses, porosity band dimensions and porosity band locations from selected die castings will be presented. The expected influence of these common microstrucutral features on mechanical properties and acceptability of die cast magnesium components for given applications are discussed.

This numerical study examines the chemical-kinetics mechanism responsible for EGR NOx reduction in standard engines. Also, it investigates the feasibility of using EGR alone in hydrogen-air and methanol-air combustion to help generate and retain the same radicals previously found to be responsible for the inducement of the autoignition (in such mixtures) in IC engines with the SONEX Combustion System (SCS) piston micro-chamber. The analysis is based on a detailed chemical kinetics mechanism (for each fuel) that includes NOx production. The mechanism for H-air-NOx combustion makes use of 19 species and 58 reactions while the methanol-air-NOx mechanism is based on the use of 49 species and 227 reactions. It was earlier postulated that the combination of thermal control and charge dilution provided by the EGR produces an alteration in the combustion mechanisms (for both the hydrogen and methanol cases) that lowers peak cycle temperatures-thus greatly reducing the production of NOx.

This paper presents an overview of the Driver Performance Data Book under preparation by the National Highway Traffic Safety Administration (NHTSA). It includes a brief discussion of the purpose of the Data Book, the restrictions placed on the development effort, and how it is expected that it will be used by Agency personnel and others. Sample pages from the document are reproduced to illustrate the basic format, and the Table of Contents of each section is presented to identify the major topics covered and indicate the number of pages devoted to each.

The Auto/Steel Partnership Corrosion Project Team has completed a perforation corrosion test program consisting of on-vehicle field exposures and various accelerated tests. Steel sheet products with eight combinations of metallic and organic coatings were tested, utilizing a simple crevice coupon design. On-vehicle exposures were conducted in St. John's and Detroit for up to seven years to establish a real-world performance standard. Identical test specimens were exposed to the various accelerated tests, and the results were compared to the real-world standard. This report documents the results of these tests, and compares the accelerated test results (including SAE J2334, GM9540P, Ford APGE, CCT-I, ASTM B117, South Florida Modified Volvo, and Kure Beach (25-meter) exposures) to the on-vehicle tests. The results are compared in terms of five criteria: extent of corrosion, rank order of material performance, degree of correlation, acceleration factor, and control of test environment.

Hydraulic fluids of the HFC category are aqueous polymer solutions with a fire resistance enhancing water content of 35 to approx. 50 %. The use of HFC fluids, above all in mobile and stationary drives in mining and in casting is subject to restrictions resulting from a number of features of a fluid. Field practice has shown that while axial-piston pumps may be successfully operated using HFC fluids, rolling bearing failures reduce their operational lifetimes. The bearing failures essentially result from material fatigue. This can be remedied by new quality steel for roller bearings. The combination of high fatigue life and corrosion resistance assures a wide application range for nitrogen-treated steel qualities.

In many situations, the root cause of a particular failure may be determined based on the observation of a single part, or perhaps a photograph, taken from the failed system. However, when failure analysis is conducted on the complete component, a different result often emerges. Such is the case described here for a piston pump that was operating on an anhydrous poly(alkylene glycol) - PAG at high pressure. Initial observation suggested the fluid was the root cause of the failure. However, when failure analysis was properly applied, it was learned that the root cause of the failure was due to mechanical failure caused by the motor-to-pump coupling. This analysis procedure is presented as a case history in this report.

There have been plastics in automobiles almost as long as there have been plastics. This paper deals with plastic molded parts from the 1930’s through 1970. These parts include steering wheels, tail light lenses, knobs, electrical connectors, fasteners, speedometer wheels, distributor caps, water pump impellers, dials, and various decorative ornaments.

A review of many years of published work has shown that hydrogen embrittlement can occur under rolling contact conditions. Breakdown of lubrication and contamination with water have been cited as the probable sources of atomic hydrogen. In this paper, a unique fracture morphology is identified and the mechanism of the fracture progression from initiation to final catastrophic failure is proposed. Development of beneficial residual compressive stress near the contacting surfaces is one approach used to avoid this type of failure. Several alternative methods capable of developing a more desirable stress distribution will be discussed.