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Flexibility, oil resistance, and the need for heat resistance to 150°C-plus temperatures have traditionally limited automotive design engineers to two options - thermoset rubber or heat-shielding conventional thermoplastic elastomers (TPE). Both of these options present limitations in part design, the ability to consolidate the number of components in a part of assembly, and on total cost. This paper presents a class of high-performance, flexible thermoplastic elastomers based on dynamically vulcanized polyacrylate (ACM) elastomer dispersed in a continuous matrix of polyamide (PA) thermoplastic. These materials are capable of sustained heat resistance to 150°C and short-term heat resistance to 175°C, without requiring heat shielding. Recent advancements in blow molding and functional testing of the PA//ACM TPEs for automotive air management (ducts) and underhood sealing applications will be shown.

As part of the 1997 Propane Vehicle Challenge, a team of twelve UTEP students converted a 1996 Dodge Grand Caravan with a 3.3 L V6 engine to dedicated Liquefied Petroleum Gas (LPG) operation according to the 1997 Propane Vehicle Challenge (PVC) competition rules (16). The 1997 UTEP team developed an LPG liquid phase port fuel injection (LPP-FI) system for the minivan. The UTEP design strategy combines simplicity and sound engineering practices with the effective use of heat resistant materials to maintain the LPG in the liquid phase at temperatures encountered in the fuel delivery system. The team identified two options for fuel storage with in-tank fuel pumps. The competition vehicle incorporates a five-manifold eight inch diameter Sleegers Engineering LPG tank fitted with a Walbro LPTS in-tank pump system, providing a calculated range of 310 city miles and 438 highway miles.

This document describes the 2-D computer-aided design (CAD) template for the HPM-1 H-point machine or HPD available from SAE. The elements of the HPD include the curve shapes, datum points and lines, and calibration references. The intended purpose for this information is to provide a master CAD reference for design and benchmarking. The content and format of the data files that are available are also described.

This document describes the 2-D computer-aided design (CAD) template for the HPM-1 H-point machine or HPD available from SAE. The elements of the HPD include the curve shapes, datum points and lines, and calibration references. The intended purpose for this information is to provide a master CAD reference for design and benchmarking. The content and format of the data files that are available are also described.

Weight reduction of automobiles is key technology in order to improve fuel economy and driving performance. Concerning of the motorcycle engine, weight reduction is also the fundamental and important technologies. Cylinder is one of the main parts of engine and the wear characteristics of the cylinder liner are largely related to the engine performance. Gray iron liners squeezed in aluminum cylinder block have been widely used. This is due to the excellent resistance to abrasion of gray iron. In order to realize light all aluminum cylinder, the good abrasion resistant method is necessary to develop to be applied with inner surface of liners. We have developed the new Rapid Composite Plating System for the motorcycle engine cylinders. This system made it possible to adopt all aluminum cylinders without cast iron liners to new type of engine.

Challenges surrounding OEM′s go far beyond to manufacture and delivery high quality vehicles. A perfect design and performance in the lowest cost possible is extremely essential to delivery to the customer the best vehicles. In order to guarantee all these targets, a robust process must be set to developed and implemented. It is known all process limitations, which faces the emergent markets and the lack of infrastructure considering the developed countries. All this limitations can deeply affect the robustness of the process. Some innovative solutions are becoming common from the engineering development combined with the manufacturing team to work out these limitations and provide excellent process stability. In this present paper it will be discussed the Bi component structural adhesive (2K PU epoxy) utilization to establish the process in the assembly line, mainly in order to improve parts dimensionally.

Engines are assigned big subjects such as low emission and low fuel consumption as well as higher output (higher efficiency) in the latest trend of environmental protection. In order to meet these requirements, Air/Fuel ratio of recent high performance engines is being arranged leaner than that of conventional engines. As a result exhaust valve seat inserts used in these engines have problems of their wear resistance because of high exhaust gas temperature. By analyzing wear mechanism under the lean burn conditions, authors developed material for exhaust valve seat inserts which show superior wear resistance under high operating temperature. For the purpose to enhance heat resistance, authors added alloy steel powder for matrix powder and used hard particles which have good diffusion with matrix. The developed material does not include Ni and Co powders for cost saving and has superior machinability.

The prime function of crown wheel pinion is to receive the power from transmission & distribute to two-wheel ends. Doing so these members will experience the tremendous bending fatigue. Shot peen is the one of the latest technology used to improve the bending fatigue of the CWP [1]. In this particular case- six CWP are taken for the study to understand the effect of the operations after shot peen process. Three Samples are named as batch A, another 3 samples are named as batch B. Both the batch CWP are shot peened. Then as a regular production practice the batch A CWP are process through hard turning ➔ Abrasive lapping ➔ Hot lubriting (manganese phosphate) ➔ Fully finish ready for assembly. Then both the batch A & batch B samples are taken for residual stress analysis using X-Ray diffraction technique. The measurement location is 50 microns below the surface. The results tabulated, found that batch A samples shows decrease in Residual stress relatively to batch B.

A catalyzed hydrocarbon (HC) trap aiming at the super-ultra low emission vehicle (SULEV) regulation was developed using a metal-impregnated zeolite. To enhance the adsorption and to raise the desorption temperature for a wide range of HC species, the modification of zeolite with certain metals was needed and Ag was found to be the most promising. Using a Ag impregnated zeolite, a three way catalyst was prepared, and its HC purification ability for a model gas simulating cold-start HCs was studied. Its heat resistance was also examined. A vehicle test for a fresh catalyzed HC trap showed that the cold-start HC after the newly developed trap almost reached the SULEV regulation level.

Automotive friction materials are composites containing three kinds of components: an organic binder, fiber for reinforcement, and property modifiers. At low braking temperatures, the wear rate of the friction materials is controlled primarily by abrasive and adhesive mechanisms. At higher braking temperatures, the wear rate increases exponentially with increasing temperature due to thermal degradation of the binder and other components, and the exponential wear rate is frequently accompanied by brake fade. Thus, one method of reducing thermal wear and fade tendency is to lower the temperature at the rotor/friction material interface. Since the rate of heat transfer from the interface is mostly dependent upon the conductive and convective modes, a rotor of high thermal conductivity will have a significant advantage over a rotor of low conductivity, if the heat capacity remains the same.

Nickel-5 Aluminum (95 % Nickel-5 % Aluminum) is widely used in the aircraft engine industry. The excellent adhesive and cohesive strength of the coating, oxidation resistance and machinability make it an ideal material as both a bond coat for subsequent topcoats and as a build up material for dimensional restoration of worn or mismachined components. Plasma spraying has traditionally been the thermal spray process used to apply nickel aluminum, and the technical properties and performance characteristics are well documented. More recently, wire arc sprayed nickel aluminum is becoming widely used as an alternative to plasma spraying due to higher bond strengths, reproducibility, better machinability and more favorable economics. This paper presents the results of a testing program designed to compare the technical properties of arc sprayed versus plasma sprayed Nickel-5 Aluminum coatings.

The vast majority of products contain joints, therefore, joining technology is key to the strategic implementation of new materials. This paper considers three innovative solutions to industrial problems ClearWeld™ A recently developed technique for laser welding materials, creating a joint almost invisible to the human eye. AdhFAST™ This novel, three-in-one fastener, allows adhesive to be injected through the middle of the device whilst retaining the joint and controlling bondline thickness Vitresyn™ Transparent plastics such as polycarbonate and acrylic have the potential to replace glass in a number of applications, car headlamps and spectacle lenses for example. However, these plastics are relatively soft materials and need protection against abrasion and scuff damage. This recently developed system gives good protection at acceptable cost

Ice adhesion characterization relies heavily on experimental data, especially when dealing with fracture parameters. In this paper, a complementary framework encompassing experimental testing with the numerical treatment of the fracture variables is proposed to provide a physical description of adhesive fracture propagation at the interface of an iced structure. The tests are based on a quasi-static flexural testing setup composed of a displacement-driven actuator and an iced plate. The measured crack length and plate deflection provide the data to be analyzed by the Virtual Crack Closure Technique in order to approximate the critical energy release rate required to study adhesive fracture propagation. The critical energy release rate in mode II is under-predicted and its value is approximated using its counterpart in mode I.

A simple contact-point based start of injection sensor has been developed for use in closed-loop injection timing control systems. The main element in this sensor is a highly durable thin film deposited by an advanced ion plating process. This sensor is expected to provide accurate detection of start of injection over all speed ranges. Sensor transient response in the feedback loop is also expected to be fast compared to other types of sensors. This detecting method can easily be applied to many kinds of injectors because of its simple structure. The durability has been confirmed by extensive testing.

Corrosion problems associated with using titanium fasteners to assemble aluminum airframe structures are reviewed. Data are presented describing the effectiveness of metallic platings and an aluminum filled organic based coating on fasteners to render the titanium-aluminum electrochemical couple inoperative. The aluminum enriched organic coating known as Hi-Kote 1 is shown to be more effective in minimizing corrosive attack on aluminum airframe structure in both saline and acidic environments. The effectiveness of Hi-Kote 1 in corrosion-fatigue tests of fastened aluminum structure is also reported.

Wet multiple plate clutches consist of friction plates, on which a friction material is bonded, and mating plates that are plain metal plates. Since the frequency and the range of load in the field of forklift trucks vary widely and are more severe than those for passenger cars, the wet multiple plate clutches on forklift trucks are often damaged. Damaged clutches that were returned from the field typically had 3 types of symptoms: 1.Only the friction material was damaged, 2.Only the mating plates were deformed, 3.Both symptoms were observed. It was clear that the cause of these symptoms depended on the difference of the operating application and the strength criteria of each part. This showed that a design guide for wet multiple plate clutches considering the strength balance between the two parts according to the work application was required. The relevant flow chart of this design process was proposed.

The classical use for zinc alloy die castings for plated trim and non-structural applications is being supplemented with new engineered applications. New alloys such as ZA-27 offer higher strengths than #3, which when combined with cost effective, net shape capability of the die casting process provide new opportunities in automotive component design. A systematic design strategy must, however, become part of the product design process. This strategy, by evaluating mechanical and physical properties of the material against use requirements, offers the best methodology for new and replacement applications.

Urethane is utilized to bond the windshield and backlite to the vehicle frame. The contribution of different modulii of glass bonding urethane adhesives on the stiffness characteristics of the vehicle is studied through finite element analysis. The modal analyses of a finite element body-in-white model with different modulii of urethanes are performed, and the analyses show that high modulus urethane makes notable contribution to the vehicle stiffness. The optimized modulus of urethane adhesive is suggested based on the analyses.

Effective use of adhesive bonding in automotive vehicle bodies requires analytical methods for durability, so that potential fatigue problems and unnecessary overdesign may be eliminated before the physical prototype stage and release of product with unquantified safety factors avoided. This paper describes a fracture mechanics-based method for predicting the durability of adhesive joints, based on work previously carried out at Volvo [1]. The method requires relatively modest modifications to a typical vehicle body FE mesh. Adhesive bonds are represented by bar elements around the periphery of each bond. Grid point forces from shell elements adjacent to the adhesive bond are recovered and used to determine line forces and moments at the edge of the glued flange. These forces and moments are then transferred to an analytical sandwich model of the joint.