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Standard

AVOIDANCE OF HYDROGEN EMBRITTLEMENT OF STEEL

2008-06-01
HISTORICAL
USCAR5-3
This standard outlines the conditions that enhance the risk of hydrogen embrittlement of steel and define the relief procedures required to minimize the risk of hydrogen embrittlement. It is intended to control the process.
Standard

AVOIDANCE OF HYDROGEN EMBRITTLEMENT OF STEEL

2012-07-01
HISTORICAL
USCAR5-4
This standard outlines the conditions that enhance the risk of hydrogen embrittlement of steel and define the relief procedures required to minimize the risk of hydrogen embrittlement. It is intended to control the process.
Standard

AVOIDANCE OF HYDROGEN EMBRITTLEMENT OF STEEL

1997-11-01
HISTORICAL
USCAR5
This standard outlines the conditions that enhance the risk of hydrogen embrittlement of steel and define the relief procedures required to minimize the risk of hydrogen embrittlement. It is intended to control the process.
Standard

Avoidance of Hydrogen Embrittlement of Steel

2002-08-22
HISTORICAL
USCAR5-1
This standard outlines the conditions that enhance the risk of hydrogen embrittlement of steel. It also defines the relief procedures required to minimize the risk of hydrogen embrittlement. SAE/USCAR-5 is intended to control the process.
Standard

Avoidance of Hydrogen Embrittlement of Steel

2007-03-01
HISTORICAL
USCAR5-2
This standard outlines the conditions that enhance the risk of hydrogen embrittlement of steel and define the relief procedures required to minimize the risk of hydrogen embrittlement. It is intended to control the process. 1.1 Hydrogen embrittlement of steel, which can cause brittle fractures under stress, occurs as a result of the absorption of hydrogen during cleaning, phosphate coating and plating processes. The susceptibility to hydrogen embrittlement increases with increasing stress (internal or externally applied stress) and increasing material strength. 1.2 Hardness readings in this specification are in Vickers scale. SAE J417 should be referred to for conversion to other scales. NOTE 1: All references to temperatures relate to part core temperature and not the indicated oven air temperature. Statistical data of verifications in temperature at the center of the oven load and oven temperature shall be established to develop the oven profile.
Standard

ELECTRICAL CONNECTOR DESIGN REQUIREMENTS

2021-01-20
CURRENT
USCAR12-6
This document gives specific and measurable design requirements to be applied at a design review prior to tooling. The specification is formatted as a checklist to aid in its use. The requirements do not apply in all situations so engineering judgment must be used. This is a specification for design; applicable performance specifications (USCAR-2, etc.) must still be performed. Specific requirements in this document are grouped by component using a prefix as shown in Table 1 and are numbered by an item number following the prefix.
Standard

Initiator Technical Requirements and Validation

2005-06-06
CURRENT
USCAR28
This specification establishes the design, performance, and validation requirements for the initiator assembly used in airbag modules, seatbelt pretensioners and/or any other Electro-Explosive Devices (EED).
Standard

NEW FINISH DEVELOPMENT DOCUMENT

2020-11-19
CURRENT
USCAR32-1
This standard lists variables that shall be investigated and reported as an initial investigation into new or revised surface finishes intended for use on fasteners. This standard provides instruction for producing a final report that will be used to determine if further investigation of a surface finish is justified. Further investigation may include tests and evaluations specific to an individual OEM prior to introduction/approval of the surface finish. The final report shall include the results, observations, and conclusions for all of the variables. The final report may be made up of several individual reports covering each variable. In all cases the laboratory performing the test, the test date and the report approver shall be included in the final report.
Standard

NEW FINISH DEVELOPMENT DOCUMENT

2007-03-13
HISTORICAL
USCAR32
This standard lists variables that shall be investigated and reported as an initial investigation into new or revised surface finishes intended for use on fasteners. This standard provides instruction for producing a final report that will be used to determine if further investigation of a surface finish is justified. Further investigation may include tests and evaluations specific to an individual OEM prior to introduction/approval of the surface finish. The final report shall include the results, observations, and conclusions for all of the variables. The final report may be made up of several individual reports covering each variable. In all cases the laboratory performing the test, the test date and the report approver shall be included in the final report.
Standard

PERFORMANCE SPECIFICATION FOR AUTOMOTIVE UNIVERSAL SERIAL BUS (USB) CONNECTION SYSTEM

2022-07-04
HISTORICAL
USCAR30
Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of any USB cable assemblies and associated connections that constitute the electrical connection systems between the consumer peripheral interface and the USB computer source in road vehicle applications. These procedures are only applicable to the USB connector and the cable. Unless otherwise specified, all of the tests listed in this specification are for both consumer and nonconsumer interface connectors.
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.
Standard

SPECIFICATION FOR TESTING AUTOMOTIVE LED MODULES

2020-08-03
CURRENT
USCAR33-1
This specification is a general level subsystem light source specification that establishes test requirements of light emitting diode (LED) components and modules for use in automotive lighting systems. The completed test data from this test specification is intended to be provided to the OEM by the Tier 1 lamp set maker as part of the lamp assembly PPAP. Re-testing shall be required if any portion of the approved LED module experiences a design, manufacturing, or component change. This document shall be applied to systems that meet the requirements for design, performance, and validation established by government standards. The LED module is defined as the LED devices and any electronics required to properly energize the LEDs using a vehicle electrical power system along with any associated electrical wiring, connectors, and thermal management system. Samples shall be tested as a subsystem and considered one test sample for the entire test sequence.
Standard

SPECIFICATION FOR TESTING AUTOMOTIVE LED MODULES

2013-02-19
HISTORICAL
USCAR33
This specification is a general level subsystem light source specification that establishes test requirements of Light Emitting Diode (LED) components and modules for use in automotive lighting systems. The completed test data to this test specification is intended to be provided to the OEM by the Tier I lamp set maker as part of the lamp assembly PPAP. Re-testing shall be required if any portion of the approved LED modules experiences a design, manufacturing or component change. This document shall be applied to systems that meet the requirements for design, performance and validation established by government standards. The LED module is defined as the LED devices and any electronics required to properly energize the LEDs using vehicle electrical power system along with any associated electrical wiring, connectors and thermal management system. Samples shall be tested as a subsystem and considered one test sample for the entire test sequence.
Standard

SPECIFICATION FOR TESTING AUTOMOTIVE LIGHT BULB SOCKETS

2020-05-28
CURRENT
USCAR15-4
This specification establishes the requirements and test procedures for automotive miniature bulb retention devices, including wedge base sockets with integral connectors, direct wire wedge base sockets, bayonet base sockets with integral connectors, direct wire bayonet base sockets, wedge base and bayonet base sockets with circuit plate assemblies, and associated interfaces. Tests shall follow the sequence shown in the flow charts in Appendices E and F whenever the following occurs: New design. Design, material, or process change made to an existing device, which could affect the outcome of the test. The test sequences shown in Appendix G shall be run annually.
Standard

Standard for Testing Automotive Miniature Bulbs

2002-04-15
HISTORICAL
USCAR3-2
The procedures contained in this specification cover the laboratory testing of miniature incandescent bulbs for use in automotive illumination and signaling 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 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.
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