This specification covers runway deicing and anti-icing products in the form of a liquid. Unless otherwise stated, all specifications referenced herein are latest (current) revision.

G-12RDP Runway Deicing Product Committee

Liquid Runway Deicing/Anti-icing Product

AMS1435E-TEST-REC (Current)03/12/2024

This specification covers runway deicing and anti-icing products in the form of a liquid. Unless otherwise stated, all specifications referenced herein are latest (current) revision.

G-12RDP Runway Deicing Product Committee

Schey’s Tribology in Metalworking: Friction, Lubrication, and Wear

B-ASM-05702/28/2024

Schey’s Tribology in Metalworking—Friction, Lubrication, and Wear is an update to the seminal text Tribology in Metalworking by John Schey, originally published by ASM International in 1983. The 1983 first edition served as a recognized essential resource for researchers in the fields of manufacturing tribology and metal forming for many decades. This 2023 update preserves the essential information in that first edition but provides a thorough update, including a description of the significant advances in tribological research and detailed information for every metal forming process.

Enhancing Microstructural Characteristics and Mechanical Properties in Friction Stir Welding of Thick Magnesium Alloy Plates through Optimization

2024-01-501402/06/2024

This research explores friction stir welding (FSW) to examine the mechanical characteristics and microstructure of thick plates manufactured from the Mg-8Al-0.5Zn alloy. Applying the FSW procedure to warm-form an Mg-8Al-0.5Zn alloy for the differential case covering the gears in the car’s automotive technology. Weld quality was significantly improved after using response surface methodology (RSM) to examine various welding parameters and find the best configurations. Improved grain refinement and phase distribution in the weld zone were found in the microstructural study of 11.5 mm thick magnesium alloy plates using RSM-optimized parameters. By dynamic recrystallization, the grain size was reduced to 16 μm, which is fifteen times smaller than the original material, thanks to the good results of single-pass FSW welding. Welding results showing high-quality characteristics such as tensile strength (161.8 MPa), elongation (27.83%), and joint efficiency (98.96%) were achieved using the

Sabari, K., Muniappan, A., Singh, Mandeep

Pre-print testing CSP-6572

SAE-PP-0915102/01/2024

Regression pre-print submission

Atash, Ganira

Methodical Design of a Subframe for a Novel Modular Chassis Concept without Knowledge of Final Vehicle Parameters

02-17-01-0006

01/22/2024

Abstract This article presents the methodical development of a subframe for a novel on-the-road-modular vehicle concept, which was developed for the U-Shift project. The subframe serves as the basis for a modular chassis. This chassis offers the possibility to exchange chassis components by the operator, which means after completion by the manufacturer, and thus to adapt the vehicle to different purposes. According to the applied methodology, the relevant wheel loads are determined and a geometric reference model is created. By defining the relevant load cases, the forces acting on the subframe, and thus the physical boundary conditions, can be determined from the wheel loads. In addition to the wheel loads and the geometric boundary conditions, no other vehicle parameters are required for the development of the subframe. The results of the topology optimization are used to identify areas of the geometric reference model that are not exposed to high loads. Based on the results of the

Weitz, Fabian, Frey, Michael, Gauterin, Frank

A Comparison of Wire Bonding vs. Spot Welding vs. Soldering in the Prevention of Thermal Runaway in a Battery Pack

2024-26-010901/16/2024

EVs are a fast-growing market and appear as a promising option against the high emission of gasoline and diesel vehicles. The growth in the EV market has been decent and a regular buyer is still skeptical due to fire incidents occurring with EVs. Complex electronics, improper thermal management, mechanical abuse, improper cell grading activities and control in production, lack of testing in a production plant, and of course, uneven degradation of cells can be one of the reasons this promising technology is facing thermal runaway and in turn, the wrath of the government and public alike. One of the reasons thermal runaway can be triggered after a cell catches fire is because a part of heat travels via busbars to the neighboring cells, as the busbars can conduct heat faster than the air. For the heat that is conducted, it is easily understandable that we need to break the electrical, as well as thermal conduction connection to the neighboring cells. This paper presents a comparison of

Pawar, Aniruddha, Khan, Faiz, Shah, Harsh, Malani, Shekhar

Evaluation of interface microstructure and bonding strength for dissimilar rotary friction welding of E46 and AA6061-T6

2024-26-019501/16/2024

Nowadays, friction welding is recognised as a highly productive and economic joining process for similar as well as dissimilar welding of automobile and aerospace components. Friction welding is the viable solution to offset the challenges of dissimilar fusion welding due to varying thermal and physical properties as well as limited mutual solubility. The main objective of this study is to evaluate the interface microstructure and interface bonding strength for dissimilar rotary friction welding of 3.15 mm E46 disc and 45 mm AA6061-T6 bar at different friction time and forging pressure. The direct drive rotary friction welding of E46 and AA6061-T6 is performed at combinations of two different friction time (4 sec and 7 sec) and forging pressure (108 MPa and 125 MPa). Mechanical bonding strength at the interface is evaluated based on the push-off and multi-step shear strength. Further, fractography of failed samples is carried out to understand the failure mechanism of welded joints

Chudasama, Gautam, Kalyankar PhD, Vivek, Chauhan, Shiv

Review on Laser welding of High Strength Aluminium alloy for Automotive Applications

2024-26-019301/16/2024

High strength aluminium alloys are an ideal material in the automotive sector leading to a significant weight reduction and enhancement in product safety. In recent past extensive development in the field of high strength steel and aluminium was undertaken. This development has been propelled due to demand for light weight automotive parts. The high strength to weight ratio possessed by Al alloy helps in reducing the total weight of the vehicle without effecting the overall performance, thereby increasing the fuel economy and reducing the carbon emission level. Joining of high strength aluminium alloy is critical to develop durable automotive products. Joining of high strength aluminium alloy for mass production in automobile industry is a challenging task. Laser welding is recognized as an advanced process to join materials with a laser beam of high-power, high-energy density. In the present study efforts are made to summarise the influence of important process parameters of laser

Sahu, Hemant, Dave, Rajeev, Chauhan, Shiv, Dwivedi, Ravi

Importance of Casting Soundness in Aluminium parts for Laser Weld Quality

2024-26-019101/16/2024

Light weight and Robust manufacturing technologies are always needed for transformation drive to the Automotive industry for next-generation vehicles with better Power to weight ratio. Innovations and process developments in materials and manufacturing processes are key to this light weighting transformation. Aluminium material has been widely used for this light weighting opportunities. However aluminium joining techniques, quality and poor consistency are limiting this transformation. This technical paper represents one of such case, where the part is made up of Aluminium through conventional casting route which affected laser weld quality due to poor casting soundness. This experiment explains in detail about the importance of Casting soundness for Laser weld Quality, Penetration, Strength etc., and the product consistency. Casting soundness improvement explored with support of Ingot quality, Die design, Gating design & Size, Overflow designs, Air vent provisions, Vacuum system etc

UMASANKAR, MAIYARASAN, Venugopal, Sivakumar, Gopalan, Vijaysankar

Damage Tolerant Fracture Assessment of Cracks in Non-Standard Geometries Under Static and Fatigue Loading

2024-26-027601/16/2024

Cracks on metallic components may appear due to manufacturing, handling, installation, repair, welding etc. and are controlled by quality documents. However, if cracks violate the limit defined in quality document, then either parts will be scraped or will need additional evaluation through detailed and specialized Linear Elastic Fracture Mechanics (LEFM) approach. The initial size, orientation and shape of crack, part geometry and loading highly impacts the behavior of crack growth and remaining useful life. Study has been performed to understand the effect of crack aspect ratio on stress intensity factor under different stress gradient scenario. This paper also provides the simplified methodology to address the multiple cracks in complex geometries under static and fatigue loading.

Puranik, Shashank Suresh, Pathan, Irfan, Shinde, Swapnil, Soni, Nitesh, Kindleysides, Andrew

Wheel Analysis Process Considering Bolt Torque Sequencing for Assembly and Disassembly

2024-26-029001/16/2024

This paper is centered on developing a methodology to simulate actual physics of the assembly and disassembly process for rear wheel components of the tractor / off highway vehicle. The components, cast wheel and sleeves, are having interference fit and are assembled through sequential bolt torquing. Effect of different torque values, torque sequence pattern and number of torquing cycles on the structural integrity of the components after assembly is studied in this process. The methodology also encompasses evaluation of residual strains during the assembly and then subsequent disassembly process of sleeves and cast wheel, while reckoning different non-linear material models for nodular and gray cast iron. The process predicts the loosening behavior of the bolts during assembly process and eventually helps to find optimum bolt torquing pattern with minimum preload loss. These are valuable inputs for factory as well as end customers to reduce number of retorquing cycles. Strain pattern

NASALAPURKAR, ANIRUDDHA P., Erisman, Phil, Mali, Kailash

A General Workflow for Static Failure Criteria and Allowable Defect Size Calculation in Presence of Defects due to Manufacturing Process and Abusive Loads

2024-26-030501/16/2024

Manufacturing processes such as casting, welding and additive manufacturing (AM) are prone to internal porosity and high surface roughness on the manufactured parts. These defects are inherent in the process and cannot be completely eliminated. Handling, transport and maintenance of manufactured parts can also lead to defects such as scratches and dents due to abusive loads. The defects can be characterized in a number of ways, assuming they resemble a U-notch or V-notch, elliptical pores, or a continuous distribution of consecutive defects in combination with surface roughness. The designer utilizes existing analytical and empirical equations to predict stress concentration due to presence of various types of defects and compute factor of safety to ensure structural integrity of design subjected to various load cases. The applicability of existing analytical and empirical equations is studied, and modifications are suggested to improve the predictions. The limits of analytical

Kishore, Prateek, Mishra, Suraj, Vemula, Sai, Puranik, Shashank, Jivani, Chinmay, Aher, Ravi

USUALLY UNOBSERVED REFINEMENTS OF AUTOMOBILE CONSTRUCTION

08000301/01/2024

ELLSWORTH, JOHN MAGEE, FAY, THOMAS J.

Optimizing a Chemical Vapor Deposition Process for a High-Performance Tungsten Material

TBMG-4980901/01/2024

PRE-print testing CSP-6572

SAE-PP-0905612/12/2023

regression preprint

Atash, Ganira

Pre-print testing CSP-6572

SAE-PP-0904512/08/2023

regression preprint submission

Atash, Ganira

Pre-print testing CSP-6572

SAE-PP-0903112/04/2023

regression preprint submission

Atash, Ganira

Print regression testing

SAE-PP-0896311/08/2023

regression preprint submission

Atash, Ganira

Preprint regression testing

SAE-PP-0896211/08/2023

regression preprint submission

Atash, Ganira

Lightweight potential and crash performance of friction stir welded Tailored Blanks

2023-01-122006/26/2023

In former papers methods to join different aluminium or different steel sheets having same thicknesses are presented using the friction stir welding process with flat tools. In order to increase the lightweight potential, the Materials Testing Institute of the University of Stuttgart, developed a novel variant of the friction stir welding process, enabling the joining of aluminium and steel sheets of different thicknesses. Compared to the conventional welding method, the difference relates to the stir welding tool used, which consists of a stepped welding pin and allows combined lap-and-butt joints to be produced. Potential applications for this innovative joining technology include lightweight components for car bodies. In this context, this paper aims to demonstrate the lightweight potential and the crash performance of Tailor Welded Blanks (TWBs) made from DX54(1 mm) and AL6016 - T4 (2 mm). For this purpose, possible parts of a car body that can be replaced with these TWBs were

Bachmann, Maximilian

test 06/19/2023auto testauto testauto testauto testauto testauto testauto testauto testauto testauto testauto testauto test

SAE-PP-0816506/19/2023

test 06/19/2023

Mutagaana, Festo

Experimental Investigation on Genetic Algorithm optimized Proportional Integral Derivative Based Active Suspension System

2025-01-001405/05/2023

In this work, Genetic Algorithm (GA) optimized Proportional Integral Derivative (PID) controller is employed. The PID gain values are optimally tuned based on the objective function formulated using the Integral Time Absolute Error (ITAE) criteria of various suspension measures like vehicle body displacement, suspension and tire deflections. The proposed GAPID controller is experimentally validated through the 3-DOF quarter-car test rig model. The fabricated model with passive suspension system (PASS) and active suspension system (ACSS) provided with an electrical actuator as base excitation is pictured. The schematic representation of the fabricated test set-up with and without ACSS is also illustrated. Further, simulation and experimental response of the fabricated model with and without ACSS are compared. It is identified that the proposed GAPID controller attenuates the sprung mass acceleration by about 41.64 % and 29.13 % compared with PASS for the theoretical as well as

A, Arivazhagan

New system for the measurement of sound-insertion loss on small samples: a comparison with ASTM-E2611 and ASTM E90 test procedures

2025-01-011605/05/2023

This article follows a companion article presented at the SAE NVC 2021, in which a new system for the measurement on small samples of the normal-incidence Insertion Loss (IL) of multilayers used for the manufacturing of automotive sound package parts was first introduced. In addition to simplifying the evaluation of the sound-insulation of multi-layers used to produce sound-package components, the system aims to overcome the limitations of the test procedure based on the ASTM E2611 standard. In this article, the latter point is demonstrated by comparing the insertion loss results obtained with the new system with those obtained with the test procedure based on the ASTM E2611 standard on a few multilayers commonly used for the manufacturing of automotive sound package parts. Results indicate that the results obtained by means of the newly developed system are more meaningful, practically usable and less prone to edge-effects, compared to those obtained according to the ASTM E2611 test

Ruggeri, Giulio, Bertolini, Claudio

Characterization and Prediction of Interior Noise Quality in Electric Vehicles through Drive Unit End-of-Line Testing (EOLT)

2025-01-003905/05/2023

This paper addresses the critical aspect of interior noise quality in electric vehicles (EVs), focusing on the characterization and prediction methodologies employed during drive unit end-of-line testing. The electric drive unit plays a pivotal role in determining the overall Noise, Vibration, and Harshness (NVH) quality of the final product. This study explores the impact of drive unit assembly process variation and individual component tolerance on the NVH characteristics of electric drive units, emphasizing their direct effect on overall vehicle acoustic quality and customer comfort. The research delves into the intricate relationship between drive unit vibrational response, vehicle interior noise, and customer subjective perception, providing valuable insights into their correlation and how they collectively influence user experience and satisfaction. It aims to enhance the understanding of how electric drive unit characteristics contribute significantly to the interior noise

Arvanitis, Anastasios, Parbat, Aniket, Jadhav, Prashant, Raphael, Andrew

Improving the Sound Transmission Loss of Wire Harness Pass Throughs

2025-01-011805/05/2023

Abstract Improving the Sound Transmission Loss of Wire Harness Pass Throughs For years the NVH community has known that openings in the dash sheet metal, such as holes to pass wire harnesses through, create an acoustical weak point that limits the potential noise reduction of the dash insulation system. These pass throughs can also be a source of water leaks into the vehicle’s interior. With the combustible engine and now electric inverter power plants, the need to seal this area is vital. By molding a lightweight barrier that draws through the fiber/absorber interior decoupler and dash sheet metal which mates to a secondary seal molded into an outer engine dash decoupler, the two opposing molded barriers meet in the engine compartment and compress together forming a seal around the wire harness. This male/female molded seal replaces the conventional snap in grommet and eliminates noise/water leaks. The system Sound Transmission Loss (STL) is equivalent to similarly insulated sheet

Check, James, Moritz, Charles

Leveraging Vision Language Models for Automated NVH Analysis

2025-01-012705/05/2023

Optimizing Noise, Vibration, and Harshness (NVH) is crucial in the automotive industry. Traditional analysis methods, including time series analytics and frequency spectrum analysis, as well as advanced techniques like time-frequency spectrogram analysis, are often time-consuming and rely heavily on expert interpretation. This research explores the potential of Vision Language Models (VLMs) specifically LLaMA 3.2 Vision, GPT-4o, and Microsoft Phi-3 vision for automating noise spectrogram analysis. By employing techniques such as few-shot learning and fine-tuning these models on a curated dataset of spectrograms paired with expert interpretations, we aim to facilitate rapid and accurate NVH assessments and report generation. The proposed approach includes assembling a dataset derived from vibration sensors and expert analyses to inform model training. Furthermore, we will evaluate the accuracy and reliability of the trained models to ensure robust performance. The techniques discussed

CHANDRASEKARAN, BALAJI, Cury, Rudoniel

Impact of tripod joint pressing load variation on drive shaft rattling in passenger car

2025-01-009705/05/2023

In today’s fast changing and competitive automotive world, vehicle NVH plays an important role in customer’s perception of the brand. A silent cabin with lower noise levels is a desired attribute in a modern car. In such a scenario, abnormal noises arising because of manufacturing variations and tolerances of components can impact the brand image of any automotive company negatively. This paper presents an investigation into a noise issue arising from the right-hand (RH) drive shaft of an automotive vehicle while driving on rough roads at approximately 30 km/h. Various technical measurements, including rotational backlash and dimensional assessments, were conducted, all of which were found within specification. However, axial play between the tripod spline and the mid-shaft spline was identified during disassembly. Further analysis revealed that material localization was the only change point in the RH drive shaft manufacturing process. The fit interference between the tripod spline

Dhankhar, Dinesh Singh, Mishra, Ashish, Kirti, Viplav, Rana, Deepak, Bhardwaj, Ashish, Singh, Karanveer

Suction Cup Quality Predication by Digital Image Correlation

2023-01-0067

04/11/2023

Vacuum suction cups are used as transforming handles in stamping lines, which are essential in developing automation and mechanization. However, the vacuum suction cup will crack due to fatigue or long-term operation or installation angle, which directly affects production productivity and safety. The better design will help increase the cups' service life. If the location of stress concentration can be predicted, this can prevent the occurrence of cracks in advance and effectively increase the service life. However, the traditional strain measurement technology cannot meet the requirements of tracking large-field stains and precise point tracking simultaneously in the same area, especially for stacking or narrow parts of the suction cups. The application must allow multiple measurements of hidden component strain information in different fields of view, which would add cost. In this study, a unique multi-camera three-dimensional digital image correlation (3D-DIC) system was designed

Guo, Bicheng, Zheng, Xiaowan, Fang, Siyuan, Yang, Lianxiang