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This paper describes the after-treatment technology that could be used to meet a future BS-VII standard, considering close-coupled SCR (cc-SCR) to help start NOx conversion earlier. Both active (Cu/Fe-SCR based) and passive (V-SCR based) systems have the potential to meet emission limits. V-SCR may be considered in the rear position because V-SCR shows a fast response with very low N2O formation. Next-gen V-SCR technology shows significantly improved performance and durability closer to Cu-SCR. The steady-state NOx conversions over Next-Gen V-SCR were better than BS-VI V-SCR in both fresh and aged-580°C/100h conditions. High durability was also observed after engine aging of 1000h (WHTC + high load). Another big challenge in BS VII could be the PN10 requirement. With enhanced filtration coating (EFC) technology, PN emissions drop drastically in comparison to Euro VI reference without EFC to meet a future BS VII.

Predicting fatigue performance in concentrated contacts under thin film (or mixed) lubrication conditions has historically involved various empirical approaches. Typically a lubrication parameter is used in an experimentally derived equation to predict the expected rolling contact performance. However, this model doesn't explain the performance improvements. Enhanced finish bearings have exhibited longer life than standard finish bearings, especially when bearings are operated with thin EHL film. In this paper, the contact surfaces of test bearings were analyzed by using a micro-macro contact model in which the macro-contact was elastic contact, and the micro-contact was elastic-plastic contact. The interior subsurface stress maps were calculated from the real contact surfaces, which included the effects of roughnesses, waviness, and profiles.

Current trends in environmental and emissions regulations are driving changes in new engine systems, and increasing the need for more effectively sealed joints in exhaust systems. At the high temperatures in these exhaust systems it is difficult for traditional gaskets to provide an effective seal, as they degrade at high operating temperatures. This paper introduces a coating that has both excellent temperature stability and good compliance, thus forming an excellent sealing enhancement for metallic layers in exhaust system gaskets. Temperature stability data is presented along with sealing data, which illustrate the superior performance of this material compared to current systems.

A new transparent type electrochromic device (ECD) has been developed. It consists of two electrochromic thin films facing each other, one of “prussian blue” (PB) and the other of tungsten trioxide (WO3). PB exhibits a high intensity of coloration and is blue in the oxidized state and transparent in the reduced state. By electrodeposition, the PB layer can be formed on large substrates at low cost. This ECD has been applied to large, curved automotive glass. It reversibly turns from dark blue to transparent at low operating voltage and maintains the same intensity of coloration without the aid of an external power supply. Compared with photochromic glass, it achieves a greater color change in a shorter time and its light absorption can be changed at will. It shields passengers from the discomfort of glare and heat flow through glass.

To reduce heat transfer between hot gas and cavity wall, thin Zirconia (ZrO2) layer (0.5mm) on the cavity surface of a forged steel piston was firstly formed by thermal spray coating aiming higher surface temperature swing precisely synchronized with flame temperature near the wall resulting in the reduction of temperature difference. However, no apparent difference in the heat loss was analyzed. To find out the reason why the heat loss was not so improved, direct observation of flame impingement to the cavity wall was carried out with the top view visualization technique, for which one of the exhaust valves was modified to a sapphire window. Local flame behavior very close to the wall was compared by macrophotography. Numerical analysis by utilizing a three-dimensional simulation was also carried out to investigate the effect of several parameters on the heat transfer coefficient.

AMS-STD-595A Color Chips Precise Color Matching, Individual Color Chips: A 3 x 5 inch color chip supplied in a 3 x 5 inch protective envelope for each AMS-STD-595 color, suitable for matching quality control inspection purposes. SAE Product Code: EA-10032 AMS-STD-595 – Colors Used in Government Procurement. This standard presents the colors used by Government Activities in a format suitable for color selection matching and for quality control inspection for paints and coatings. Standard is used with DoD and other Federal Agencies as a primary source of color reference.

This SAE Standard includes complete general and dimensional specifications for those types of pipe, filler, and drain plugs (shown in Figures 1 to 6 and Tables 1 to 4) commonly used in automotive and related industrial applications.

The present work has the objective to quantify and evaluate abrasive wear resistance of a hard coating. It is obtained by weld deposition of an iron based alloy containing Cr and Nb as carbide forming elements, and to compare it to wear resistance of a heat treated SAE 5160 steel, normally used for agricultural equipment. Wear resistance was determined from two body and a three body abrasion tests using pin abrasion test equipment and a rubber wheel abrasion test, respectively.

This paper details advances in phosphate and oil technology for protective coatings that has produced a new product more responsive to use requirements, economical I easy to handle, simple to apply and can withstand 400 plus hours in neutral salt spray testing.

This presentation discusses the effectiveness of aftermarket paint, vinyl, and fabric protection services as they relate to the appearance and maintenance of the vehicle from the customer’s perception. For paint protection, luster, depth of gloss, durability etc., will be measured by various accelerated laboratory tests. For vinyl protection, both laboratory tests and outdoor exposure will be used to show that preservation of the vinyl is possible. Finally, for fabric protection, anti-soiling, flammability and wear tests among others will be used to show that fabric life and appearance can be extended.

Commercial heavy truck drum linings of 4 different compositions were tested using the Chase tester under constant loads and temperatures at a constant speed in order to find out how lining wear might affect the friction coefficient. When the lining wear increases, the friction coefficient increases linearly under a condition of constant load, speed and temperature. However, when the lining wear approaches zero, the friction coefficient still remains relatively high, indicating other factors are also involved in controlling friction such as interface deformation and others. As the temperature increases or the load increases, the wear contribution to the friction becomes less and less effective. All these observations are discussed and explained in terms of wear particle formation and friction film behavior.

Abstract Insulating combustion chamber surfaces with thermal barrier coatings (TBCs) provides thermal efficiency improvement when done appropriately. This article reports on insulation heat transfer, engine performance characteristics, and damage modelling of “temperature swing” TBCs. “Temperature swing” insulation refers to the insulation material applied on surfaces of combustion chamber walls that enables selective manipulation of its surface temperature profile over the four strokes of an engine cycle. A combined GT Suite-ANSYS Fluent simulation methodology is developed to investigate the impact of thermal properties and insulation thickness for a variety of TBC materials for its “temperature swing” characteristics. This one-dimensional transient heat conduction analyses and engine cycle simulations are performed using scaled-down thermal properties of yttria-stabilized zirconia.

This paper deals with an analytical method to calculate the press-fit tolerance and fits between gears and shaft for automotive applications. The relative interferences increase sharply in the small diameter range, therefore one must be especially careful when designing small diameter joints. The strength of press-fit depends on the amount of relative interference; extreme interference leads to excessive contact stresses between the gear and shaft eventually leading to failure. Too little interference leads to slippage of gear on the shaft. In the press fit connection a shaft's spline rolling operation and gear internal broaching is eliminated. It is more economical than a conventional spline connection. Press fit connections are used in various transmission between a shaft and a gear. They are used in 6 speed transmission to 9-speed transmission for (German based Vehicle Manufacturer) heavy and light commercial vehicle company.

AIL trucks produced in the Second Automobile Works(SAW), with annual capacity of 100,000 trucks, have adopted leaf springs with double-grooves incorporated on the compression side. A Silicon-Manganese-Vanadium-Boron grade steel (55SiMnVB) was developed with very low tendency of decarburization in heating and very good hardenability on quenching. With rational cross-sectional configuration, a reduction in weight of 10.5% of spring assembly is realized. SAW adopts unique induction heating of spring leaves. The exceedingly short time of heating further excludes the possibility of decarburization. Another unique technology is individual cooling of spring leaves. After tempering, spring leaves undergo pre-stressing shot-peening. The final process is electrostatic coating with infrared drying.

For more than 25 years the Lambda ratio (λ) has been used as an indicator of the lubricant regime in an operating contact within either bearings or gear sets. λ is determined when the lubricant film thickness (h) within the contact is divided by the composite roughness (σ) of the two surfaces forming the contact. Recommendations of appropriate film thickness equations and surface roughness values are made to provide a modified lambda ratio (λm) that better represents the lubricant regime within bearings or gears. In recent years bearing performance, especially as related to fatigue life, has increased significantly. This is primarily due to cleaner steels but also from better surface finishes and bearing internal geometries. With λm and an understanding of how contact fatigue damage mode relates to a wide range of λm values, it may be possible to provide gear sets with improved performance similar to that now available in bearings.

Solving the driver distraction problem Is voice-recognition technology the silver bullet? No, engineers agree, but it has its place. Succeeding in the alliance game It was General Motors' Arvin F. Mueller, Chairperson of the SAE 2001 World Congress, who came up with "Succeeding in the Alliance Game" as the theme for the March 5-8 automotive engineering event in Detroit. Ferrari 360 aerodynamic development The search for downforce without aerodyamic devices, such as wings or spoilers, led to novel solutions for the car's suspension. Renault's Euro 3 engine Flexible injection systems allowed Renault VI engineers to balance many conflicting priorities in developing Europe's first heavy-duty diesel engine with a fully electronic high-injection-pressure common-rail injection system. Meeting future emissions standards with diesel SUVs AVL List believes that diesel engines could be one way to improve the environmental acceptance of sport utility vehicles.

The bake hardening effect depends on three parameters i.e. pre-straining, paint baking temperature and paint baking time. The combined effect of all these parameters results into the increase in yield strength, called the “baking effect”. This paper explains the individual effects of these parameters on the baking value. Tensile test were carried out for the 495 samples baked at baking temperature from 140°C to 250°C with differential baking time of 10, 15, 20, 25 and 30 minutes and differential pre-straining of 2%, 3% and 5%. The differences of yield strength between the unbaked and baked sample were calculated and the increase in yield strength was noted. After these laboratory trials 800 numbers of door outer panels of a small truck were formed and finish painted. The increment in yield strength after component forming and painting was determined by taking tensile samples from three different locations of 5 painted doors.

The code provides test procedures and methods of calculating a brake rating from the data obtained for brakes used in highway commercial vehicles over 4.5 T (10 000 lbs) GVWR air and hydraulic. Some general correlation may be expected between brake ratings established by this means and those obtained from vehicle tests such as outlined in SAE J880. The brake rating power, kW (hp) calculated by conduct of this code is an arbitrary index of performance of the brake and drum when tested by this procedure and may be appreciably different from the values obtained by other techniques.

A new process for high production rate finish grinding of hardened spiral bevel and hypoid gears has been developed. The use of cubic boron nitride (CBN) grinding wheels permits rapid metal removal rates and long grinding wheel life, while producing more consistently accurate results. The methods and results of the CBN gear grinding are described.

This SAE Recommended Practice pertains to blast cleaning and shot peening and provides for standard cast shot and grit size numbers. For shot, this number corresponds with the opening of the nominal test sieve, in ten thousandths of inches1, preceded by an S. For grit, this number corresponds with the sieve designation of the nominal test sieve with the prefix G added. These sieves are in accordance with ASTM E11. The accompanying shot and grit classifications and size designations were formulated by representatives of shot and grit suppliers, equipment manufacturers, and automotive users.