Browse Topic: Manufacturing processes

Items (10,396)

Elbow Assembly 45°, Flared Tube to Retained Nut, for Seal Ring** FK Test-2026-04-12 **

5/8/2026

SCOPE IS UNAVAILABLE.1

G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies

Technical Insight into Experimental Payload Design, Fabrication, Integration, and Clearance Methodology Applied in Vertical Lift Flight Test Research

F-0082-2026-0314

5/5/2026

This organizational process survey provides insight into the technical aspects of approved airworthy aircraft modifications applied in government organization vertical lift flight test. The publication reviews processes applied by the National Research Council of Canada's Flight Research Laboratory (NRC-FRL) and its Airworthiness Control System to enable research flight testing. Dominated by the need for integrating experimental payloads, the NRC-FRL embeds a Design and Fabrication Service organization for modification of internal and external client projects and flight test aircraft. In context of experimental flight testing, this work reviews technical information on process, facilities, and methodology for airworthy integration of flight test payloads. Information is used to synthesize recommendations in experimental vertical lift flight testing that satisfy both formal (regulated compliance) and informal (compliance intent) airworthiness requirements.

Alexander, Marc, Long, Terry, Lebrun, Camile, Day, James, Melnik, Harley, Thomas, Jeffrey

testing new software product

SAE-SUP-TEST13

4/1/2026

Software Diagram https://wcm14-tst.cld.sae.org/site/binaries/content/gallery/mobilus-brx/digital-supplements/software-diagram.png/software-diagram.png/sae%3Amedium

Analysis and Optimization of Stick-Slip Behaviour in Metal-Plastic Interfaces for Connected Tail Lamp Assemblies in Electric Vehicles

2026-26-03321/16/2026

The seamless and sleek design of connected tail lamps adds a visually striking element to the car's exterior. It aligns with contemporary automotive trends and gives the vehicle a premium and futuristic appearance. Automakers use these lamps as a design signature to establish brand identity. Connected tail lamps improve visibility for drivers behind the vehicle. The assembly of connected tail lamps can pose several challenges, especially due to their complex design and integration requirements. Metal-plastic creak is a common concern in electric vehicles (EVs), often noticeable when driving on uneven roads. This primarily results from stick-slip behaviour at the interface of metal and plastic components, intensified by improper alignment. When the designed geometric dimensioning and tolerancing (GD&T) is not met in real manufacturing conditions, misalignment introduces unintended contact forces, leading to intermittent micro-sliding and frictional energy release, which manifests as an

MICHAEL STEPHAN, NAVIN ESTAC RAJA, C M, MITHUN, Mohammed, Riyazuddin

A Study on the Microstructural Changes and Corrosion Behavior and Mechanical Properties in Stainless Steel Welds with Single Versus Double Stabilized Welding Wires

2026-26-02881/16/2026

This research investigates the influence of stainless-steel stabilization, using single (titanium) and double (titanium and niobium) stabilized ferritic weld wires, on the metallurgical, mechanical, and corrosion behaviors of weld seams and their heat-affected zones (HAZ). Two ferritic stainless-steel samples, one stabilized with titanium (Sample No. 1) and the other with titanium and niobium (Sample No. 2), were selected for this comparative study. The research involved comprehensive analysis, including fatigue testing of the welded joints produced by both types of wires (430LNb & 430LNbTi), correlated with detailed microstructural and mechanical characterization. Metallographic analysis via optical microscopy revealed distinct features of the HAZ and weld seam, focusing on grain size, shape, and weld geometry. Micro-hardness measurements were conducted to elucidate the mechanical properties of the weld seams. Tensile testing was performed using a Universal Testing Machine to assess

Gaware, Amol Chandrakant

Transforming Manufacturing: Increasing Throughput and Reducing production Complexity with Digital Twins

2026-26-04491/16/2026

In traditional manufacturing, increasing production line capacity often involves physical trials, leading to downtime, high costs, and operational risks. This paper presents a bidirectional digital twin developed for the Fischertechnik Smart Factory Kit, enabling real-time simulation and validation of production line modifications before actual deployment. The digital twin integrates with a Siemens PLC to mirror real-world operations, capturing live production data and visualizing key parameters like cycle time and machine utilization in a 3D environment. Engineers can test various optimization scenarios adjusting conveyor speeds, optimizing robot paths, and modifying buffer sizes to enhance efficiency. The best-performing configurations are identified based on throughput, cycle time, and resource utilization, and validated changes are automatically deployed to the PLC, ensuring seamless implementation. Beyond capacity optimization, this solution improves overall production efficiency

Kumar, Rahul, Singh, Randhir

Balancing global and local formability properties through Nb microalloying

2026-26-03031/16/2026

David Martin, CBMM Asia Bernardo Barile, CBMM Europe BV Caio Pisano, CBMM Europe BV Automotive high strength steels have specific microstructure-dependent forming characteristics. Global formability is generally associated with high uniform strain values which imply good drawability and stretch forming properties driven by pronounced work hardening. Local formability on the other hand is often measured by various fracture strain values—generally higher in single phase steels. In this respect, the so-called ‘local/global formability map’ concept has been established not only to provide a comprehensive methodology to characterize existing automotive steels but also to enable improvement strategies toward more balanced forming characteristics. Niobium (Nb) microalloying is a powerful tool to achieve both property improvement in general and property balance in particular. More than two decades of research has demonstrated that Nb-induced microstructural optimization is applicable to HSLA

Barile, Bernardo

Simulation driven design of robust Crank-train systems for elevated In-cylinder combustion pressure

2026-26-04001/16/2026

The need for increased in-cylinder pressure to meet the higher engine rating and stringent emissions norms requires special attention on the Main moving components torsional behaviour and the bearing performance. The work presented in this paper utilizes the 1D and 3D simulation potential of AVL EXCITE for the assessment of design changes required in Crank-Train system for the increased in-cylinder pressure from 170bar to 220bar. The key feature of the executed work was that all the design changes were accommodated with minimal changes in packaging / layout interfaces. The given work was executed on 6-Cylinder Turbocharged In-cylinder with Type V valve-train configurations. Initial brain storming & 0d calculation helped in understanding the design optimization required in each and every crank-train parts. Considering the guidelines available in terms of L/d ratio for the bearing, connecting rod length, the overall linkage specification was set up for starting with design work for

Khandelwal, Meha

Innovative Friction Locking Mechanism for High Voltage Busbar Connections in EV Batteries

2026-26-01551/16/2026

In the development of high-voltage (HV) batteries, ensuring secure connections between HV conductors and maintaining the safety and performance of the battery pack is paramount. Therefore, In the pursuit of enhancing efficiency and reliability in electrical connections, this paper explores the innovative alternate for a traditional screwing method with a friction locking mechanism for connecting busbars. The novel design reimagines the busbar as a Friction clamp (Female part) that securely holds the male part of the Busbar, significantly increasing the contact surface area up to 50%. This enhanced surface area not only improves electrical conductivity but also reduces heat generation, addressing common issues associated with traditional screw-based connections. By eliminating the need for screws, the new design streamlines the assembly process, resulting in reduced cycle times and improved overall assembly line efficiency. This study presents the design methodology, performance

Venkatesh, Murali, Raghu, Arun, Bhramanna, Amol

Virtual Reality in Assembly Simulations: Outpacing Tecnomatix Process Simulate for Faster Time-to-Market

2026-26-03981/16/2026

Virtual Reality (VR) technology is emerging as a transformative solution in manufacturing industry. It offers significant advantages over traditional tools like Tecnomatix Process Simulate (PS) in assembly and ergonomic simulations. Analysis using PS is time consuming and lacks real time human interaction as it relies on detailed modelling and sequential workflows, which will delay the identification of assembly no-build conditions and ergonomic issues. This paper evaluates the time and cost saving potential of VR in assembly processes and explores its role in minimizing the need for physical prototypes across various stages of vehicle development. VR provides interactive environments, enabling interaction with 3D models and real-time collaboration with various teams across the globe. This leads to faster identification of assembly process flaws, quicker iteration cycles, and a reduced need for physical prototypes in the station development process for the lines. VR allows individuals

Nagendran, Rakesh Kumar

Reliability of Rubber Grommets by Stochastic Analysis of Geometric Tolerances

2026-26-05011/16/2026

Manufacturing tolerances pose considerable challenges in the production of rubber-based components, often leading to dimensional variations that can compromise overall product reliability. These inconsistencies may result in a range of functional issues, including poor sealing, excessive wear, misfit during assembly, and premature failure. Among these components, grommets are especially sensitive due to the complex, non-linear behavior of rubber materials, making precise dimensional control critical to ensure consistent and dependable performance. Even minor deviations in grommet geometry can trigger substantial assembly difficulties. Issues such as misalignment, buckling, insertion challenges, and potential damage to neighboring parts are commonly encountered. These complications typically require multiple rounds of design revisions and physical testing, which extend development timelines and significantly increase production costs. Real-world observations from various automotive

Beesetti, Siva, Hattarke, Mallikarjun, James Aricatt, John, PATHAN, ERAM

Numerical Investigation on Thermo-Mechanical Characteristics of Injection-Molded Thermoplastics using Anisotropic Material Properties

2026-26-02801/16/2026

This paper presents a comprehensive numerical method intended at developing a coupled process structure simulation that integrates both elastoplastic and anisotropic material behavior for short glass fiber-reinforced injection-molded thermoplastics. Three engineering tools, namely Moldflow, Digimat, and ABAQUS are used in the current numerical methodology to assess material anisotropy and its influence on thermo-mechanical characteristics. The simulation incorporates fiber orientation concerns as well as potential injection molding defects known as weld lines, linking with thermo-mechanical simulations. The behavior of real injection-molded components is computationally represented by the ability to transfer data from injection molding software (Moldflow) to structural software (ABAQUS). Besides, integrating with multi-scale modeling software Digimat as an interface tool, the results of the Moldflow simulations, such as fiber orientations and weld-line properties transmitted directly

T, KALINGA, Yanamadala, Dharma Teja, Mattupalli, Venkata, Chirravuri, Bhaskara, Miller, Ronald

Manufacturing process advancement in CNG Exhaust Valve to prevent seat wear issue

2026-26-02781/16/2026

Exhaust Valve CNG market share increased in India in recent years demanding for more durable and reliable CNG Engine. While in current scenario durability is one of the major concerns for CNG engine. Major issue faced in CNG powertrain is high wear at Exhaust valve CNG face due to excessive wear. In Current practice T400 Sintered material layer is deposited at Valve face which is very critical to achieve less wear at valve face. Due to manufacturing variability high level of variation is found mechanical properties of T400 deposit which is very critical for Exhaust Valve CNG performance. In this paper all important process parameters are discussed for achieving consistent Exhaust Valve CNG T400 deposit quality. Each process parameter detail impact on T400 material is studied and explained to achieve consistent quality of T400 deposit leading to robust design of Exhaust Valve CNG.

Poonia, Sanjay, KUMAR, CHANDAN

For CNG and FFV fuel application robustness improvement of Exhaust Valve

2026-26-01251/16/2026

Today, globally, automotive manufacturers are striving to meet the increasing demand for fuel economy, high performance, and silent engines. The fundamental approach to achieving these requirements is through designing low friction mechanisms, resulting in less wear and higher durability. The demand for CNG vehicles has surged exponentially in recent years, prompting increased government focus on alternative fuels such as CNG and hydrogen. These dry fuels lack lubricating properties, unlike conventional fuels like petrol, diesel, and biofuels, which are wet and liquid. Consequently, the operations and failures associated with these fuels differ. The materials and designs of engine parts, such as fuel lines, ECU, exhaust valves, and cylinder heads, vary depending on the fuel used. This study discusses the countermeasures adopted to address the high seat and guide wear in cylinder heads and valves. The investigation focuses on material, design, and manufacturing process improvements

Poonia, Sanjay, KUMAR, CHANDAN

Development of a GUI-Based Pitch Sequence Optimization Tool for Tyre Noise Reduction

2026-26-03301/16/2026

Minimizing tyre noise is essential for enhancing ride comfort, especially in electric vehicles where the absence of engine noise makes tyre-generated sound more prominent. This work presents the development of a GUI-based pitch sequence optimization tool to support tyre design engineers in generating acoustically optimized tread sequences. The tool operates in two modes: without constraints, where the pitch sequence is optimized freely to reduce tonal noise levels; and with constraints, where specific design rules are applied to preserve pattern consistency and manufacturability. This tool plays a pivotal role in the tire development process, serving as one of the key evaluation criteria for tread pattern approval before mould fabrication. By enabling engineers to generate balanced, low-noise pitch sequences that align with both acoustic targets and engineering constraints, the tool facilitates faster design iterations and smooth integration with downstream processes. Its successful

Sampathraghavan, Lakshmi, Ramarathnam, Krishna Kumar, Mantripragada PhD, Krishna Teja, Ramachandran, Neeraj

Study of Style wheel rim failure Due to Rim and disc assembly interference

2026-26-05411/16/2026

This study focuses on the investigation of wheel rim failures near weld zone during repeated cornering induced by interference between the rim and disc during the wheel manufacturing assembly process. Strain gauges were employed to capture real-time stress and strain distributions at critical zones during interference fitting. The experimental results revealed that improper interference levels lead to significant stress concentrations, often surpassing the material's elastic limit, initiating micro-crack formation and promoting fatigue failure. Detailed strain analysis indicated that both radial and axial stresses contribute to long-term structural degradation. The study highlights the critical role of dimensional tolerances, surface finishes, and assembly forces in minimizing stress-induced failures. Recommendations are provided for optimizing design and assembly practices to enhance the durability and reliability of automotive wheels.

P, Praveen, DEsigan, Lakshmipathy, K, CHANDRAMOHAN, C, Santhosh

Failure Analysis of Dissimilar Metal Weld Joint of an Air Spring Bracket within an Automotive Active Seat Suspension System

2026-26-04871/16/2026

In modern four-wheelers, seat suspension systems play a crucial role in enhancing occupant comfort by mitigating the effects of road unevenness and vibrations. Among these systems, active suspension mechanisms offer advanced performance through complex assemblies involving welded, riveted, and bolted joints. This study investigates the failure of an air spring bracket - a critical component of a pneumatic active suspension system - manufactured by Gas Metal Arc Welding (GMAW) of two dissimilar ferrous materials which are likely to be SAPH440 and S355J2. These different materials were used based on mechanical properties required to perform by their particular part. System level validation tests were conducted to ensure the reliability of the seat suspension system. The one of the validation tests is continuous cyclic fatigue test which is carried out on the complete seat assembly. However, during vibration / cyclic endurance testing, premature failures were observed near the weld joints

Patale Jr, Reshma, PINJARI, JAYANT NAMDEV, BALI, SHIRISH

"Design and process Optimization of Suspension Components Under RWUP-based Loading Conditions"

2026-26-05141/16/2026

Title: Challenges faced during design and manufacturing of POM (Polyoxymethylene) ring in Macpherson strut suspension. Abstract: Designing and manufacturing a POM (Polyoxymethylene) ring for a MacPherson strut suspension system brings a unique set of challenges due to the high-performance and durability demands for Indian road application. POM ring along with bump used in the shock absorber is designed to absorb the strong shock coming from the road inputs when suspension travel reached to the maximum limit there by absorbing the impact energy and preventing it from transferring it to the body. A bump stopper for a suspension of a vehicle is made of poly urethane (PU) and POM ring (Polyoxymethylene). The bump stopper forms of a bellows shape during the absorption of impact energy. Bellow or wrinkle in which concaves and convexes are repeated is formed on the outer surface of the bump stopper. POM ring is placed in the concaves of bump stopper which will define load, deflection

Koritala, Ashok Kumar, Malekar, Amit, kulkarni, Purushottam, S, SIVASHANKAR, Mishra, Harshit, Ganesh, Mohan Selvakumar, Patnala, Avinash, J, Ramkumar, NAYAK, Bhargav, M, Sudhan

Virtual Paint Shop: Automotive E-coating Process

2026-26-03651/16/2026

The automotive paint shop is one of the most energy-intensive processes in vehicle manufacturing. This drives automotive OEMs to continuously improve production efficiency and reduce operational costs through digital twin technologies. Additionally, the push for shorter time-to-market emphasizes the need for simulation-based manufacturing processes—such as virtual testing and CAE simulations—to enable faster, data-driven decision-making early in the product development cycle, ultimately reducing cost and development time. Among the various stages in the paint shop, two of the most critical are: 1. Electro-dip coating (E-coating), also known as Electro-Deposition coating, which applies a corrosion-resistant primer to the Body-in-White (BIW). 2. Oven curing, which ensures the primer is properly bonded and cured for long-term protection and finish quality. To optimize these processes, a Dip-Drain-E-Coating simulation was developed using Siemens Simcenter STAR-CCM+. This simulation

Gundavarapu, V S Kumar, p, Vivekaanandan, Garg, Manish, Navelkar, Tanay, BS, Balachandran

UNIQUE HYBRID PANORAMIC HEADLINER CLIP WITH HIGH TOLERANCE TO REPLACE DUAL LOCK FASTENERS

2026-26-02991/16/2026

Mounting strategies for vehicles with panoramic sunroofs remains a challenge owing to its high complexity to balance cost, performance and assembly efficiency. Achieving efficient and reliable headliner mounting solutions is one of the conundrums where cost optimization must go together with uncompromised performance. Traditional methods like Dual Lock Fasteners (DLFs), have set high benchmarks for robustness but at the cost of increased manufacturing complexity and expense. In pursuit of a more economical and production-friendly alternative, various plastic clip designs were explored. However, these solutions posed significant challenges during validation due to the stringent requirements for mounting feasibility, tolerance management, and long-term durability This paper introduces a novel hybrid plastic-metal clip solution that addresses those challenges comprehensively. The new design achieves precise tolerance control, ensuring reliable headliner installation under varying Body-in

D, GOWTHAM, Kumarasamy, Raj Ganesh, Shoeb, Mohd, Chauhan, Aarti

Effect of pipe bending by rotary tube bending process on durability of frame structure

2026-26-03701/16/2026

For Original Equipment Manufacturers (OEMs), ensuring the overall quality of two-wheeler frames hinges on robust process capability and meticulous design considerations. A comprehensive Computer-Aided Engineering (CAE) simulation approach, integrating manufacturing processes and design elements, is vital for achieving optimal durability. This study focuses on developing such an approach through detailed finite element analysis of Cold Electric Welded (CEW) annealed round pipes used in frame construction. We simulate the bending process, capturing structural deformation and residual stresses. A 3D mechanical model with realistic tooling geometries and contact interactions accurately represents shape changes, ovality, and wall thickness redistribution. Unlike Electric Resistance Welded (ERW) pipes, CEW pipes, due to annealing, offer a stress-free initial state, allowing precise deformation analysis. Simulation results demonstrate significant geometric alterations in the bend zone

Rajwani, Ishwar, khare, Saharash

Simulating Performance of Adhesive-Bonded Joints for Automotive Applications

2026-26-04151/16/2026

Adhesive joining techniques have rapidly gained momentum in the automotive industry over the past decade, offering several advantages over traditional joining methods. The complex design requirements of modern automobiles have increased the demand for intricately shaped components, where conventional spot/seam welding and mechanical fastening are often not feasible. Unlike spot and arc welding, adhesives do not degrade the properties of the substrate. Moreover, they enable the joining of components made from dissimilar materials, thus contributing to the overall weight reduction of assemblies. Adhesives also provide damping effects, reducing noise, vibration, and harshness (NVH), thereby contributing to a quieter and more comfortable ride. Additionally, adhesives enhance structural integrity by distributing stresses more uniformly across the joints. Consequently, understanding the simulation and failure prediction of adhesive joints has become essential. Traditional failure criteria

Parambathuvalappil, Rahul, Patil, Sanjay

Evaluating the Suitability of ADC12 for Sand Casting: Filling, Solidification, and Mechanical Properties

2026-26-02961/16/2026

This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines

Subramani, Rajesh, Jichkar, Pawan

A study on the thermal degradation of chlorinated Polyethylene rubber

2026-26-02761/16/2026

Elastomeric materials are essential in advanced automotive engineering for mobility, isolation, damping, fluid transfer (cooling, steering, fuel, and brake), and sealing because of their unique physio mechanical properties. Elastomers are commonly used in both static and dynamic components, such as hoses, mounts, bushes, and tires. Engine emission standards and weight optimization have caused higher temperature exposure conditions for automotive components. The steering system uses special purpose elastomers like Chlorinated Polyethylene that can deteriorate under abnormal conditions during vehicle operation or manufacturing process due to the high temperature exposure. Therefore, it is crucial to comprehend the causes and consequences of thermal degradation of elastomers. Thermal degradation is a significant phenomenon that changes the physical and chemical properties of elastomers, which results in a product not meeting functional requirements. This study investigates the thermal

THIRUPPATHI, ANANDHI, Mishra, Nitish, Krishnamoorthy, Kunju

A numerical approach to optimize the flow characteristics for the enhancement of casting soundness of Al 6061 alloy die-casting

2026-26-02841/16/2026

The optimization of flow characteristics such as filling time, flow velocity, viscosity and temperature play a vital role in the die-casting to enhance the casting soundness. Experimental trial and error methods for optimizing the flow characteristics of mold filling are costlier and time-consuming methods. A digital approach could significantly minimize the cost and time for the prediction of the flow characteristics of the casting. Z-Cast Pro is the casting simulation software used for simulating the whole casting process such as filling, solidification etc. This software basically utilizes the finite difference and finite volume approximation techniques to numerically unravel the molten metal flow and solidification equations. In this study, A 3D model of the valve housing is used to analyze the mold-filling behavior through high and low-speed plunger movement of the molten Al 6061 alloy using Z-Cast Pro software version 24. Higher-speed plunger movement required a total mold

Choudhary, Chandan, Subramaniam, Anand, Karle, Manish, Karle, Ujjwala

Incorporation of strain hardening and sheet thinning effects during forming process for an accurate prediction of buckling loads on sheet metal axle parts

2026-26-03911/16/2026

In this competitive automotive world, shorter development time and quicker time to market for new models are vital to product success. This can be achieved by digitalization, thereby avoiding over-design of parts and the need for physical prototypes, resulting in cutting down on material and development efforts respectively. In this study, the deviation of load carrying capacity of chassis sheet metal axle links in comparison with hardware testing and simulation results were investigated. A multi-step forming simulation is carried out, which involves simulating all stages of the forming process to accurately predict the plastic strains leading to material strain hardening and thickness distribution leading to thinning. The forming simulation is performed using the anisotropic material model Banabic-Barlat-Comsa (BBC) to capture the anisotropy effects. This model uses several coefficients to precisely characterize the yield surfaces, considering both uniaxial and biaxial yield stresses

R B, Govind, Selvaraj, Nirmal Velgin

Enhancing Factory Modelling: Integrating Drone Technology and Automated Post Processing Systems

2026-26-03071/16/2026

The growing environmental, economic, and social challenges have spurred a demand for cleaner mobility solutions. In response to the transformative changes in the automotive sector, manufacturers must prioritize digital validation of products, manufacturing processes, and tools prior to mass production. This ensures efficiency, accuracy, and cost-effectiveness. By utilizing 3D modeling of factory layouts, factory planners can digitally validate production line changes, substantially reducing costs when introducing new products. One key innovation involves creating 3D models using point cloud data from factory scans. Traditional factory scanning processes face limitations like blind spots and periodic scanning intervals. This research proposes using drones equipped with LiDAR (Light Detection and Ranging) technology for 3D scanning, enabling real-time mapping, autonomous operation, and efficient data collection. Drones can navigate complex areas, access small spaces, and optimize factory

Narad, Akshay Maruti, C H, Ajheyasimha, Vijayasekaran, Vinothkumar, FASGE, ABHISHEK

CAE driven seam weld optimization for stiffness and fatigue calculations

2026-26-04781/16/2026

Structural parts are joined using seam welds, spot welds and bolted connections. The strength and stiffness of any structural part are strongly influenced by the properties of their joints. Seam welds are used extensively in the automotive industry to join panels. The design and the positioning of the seam welds have a significant impact on the technical cost of the project. In the automotive industry, structural optimization and fatigue simulation have become standard applications during any development process. The conventional approach in identifying the position and number of seam welds and its length is time consuming and leads to over design. Current paper highlights developing a simulation process for seam weld optimization in identifying the optimal position and length of seam welds. The optimization workflow is set up in CAE with design objective of minimizing the number of seam welds and finding the optimal length by meeting stiffness targets and fatigue life of seam welds

Gudipati, Raja Shekar Reddy

AI-Driven Predictive Methodology for Bolt Integrity in Vehicle Durability Testing

2026-26-06481/16/2026

The application of AI/ML techniques to predict truck tailgate bolt loosening represents a major innovation for the automotive industry, aligning with the principles of Industry 4.0. Traditional physical testing methods are both expensive and time-consuming, often identifying issues late in the development process and necessitating costly design changes and prototype builds. By harnessing AI/ML, manufacturers can now analyze tailgate slam and bolt preload data to accurately forecast potential bolt loosening issues. This predictive capability not only enhances quality and safety standards but also significantly reduces the costs associated with tooling and builds. The AI/ML tool described in this paper can simulate a variety of load conditions and predict bolt loosening with over 90% accuracy, considering factors such as changes in loads, bolt diameters, washer sizes, and unexpected masses added to the tailgate. It provides valuable design insights, such as recommending optimal bolt

Sivakrishna, Masani, Das, Mahat, Singh, Abhinav, karra, Manasa, Shienh, Gurpreet, Luebke, Amy

Hydrogen Embrittlement in Galvanized High Carbon Steel Components of Automotive Seat Slider Assembly

2026-26-03021/16/2026

This research paper investigates the failure of an isolator clip used in the seat slider assembly, which guides and restricts the sliding motion of the tooth bracket within the seat. The component is made of C80 high-carbon spring steel, known for its high strength. According to the manufacturing process details, zinc plating was applied to the component for corrosion protection, as confirmed by EDS analysis. A fractographic examination of the failed part revealed a brittle, intergranular fracture morphology with visible cracks. Certain areas also exhibited micro-void coalescence, indicating a dimpled fracture surface. The primary failure mode was intergranular (IG) fracture. The delayed fracture was attributed to intergranular fracture mechanisms, micro-void coalescence, and the high strength of the steel, which made the component susceptible to hydrogen embrittlement. Hydrogen embrittlement occurs when hydrogen atoms become trapped along the grain boundaries, where they form hydrogen

Saindane, Mehul Kishor, BALI, SHIRISH

Data analytics methodology for vehicle quality complaint analysis

2026-26-06541/16/2026

Automobiles have become a part of people's everyday life. Customers base their trust on a brand's reputation while making a buying decision. With the evolving trends, feature advancements, automobiles have become a complex system. Ensuring product quality amidst system complexities is necessary to maintain the brand value & ensure customer satisfaction. Efficient addressal of customer quality complaints is pivotal in maintaining product quality. Until recent times, manual analysis using traditional data processing tools has been used for vehicle complaint analysis. However, considering the large quantum of data in new age vehicles with more number of control units, it becomes time-consuming, expertise dependent and susceptible to human errors. Given this & the advent of new age machine learning techniques & data analysis tools that can handle large amount of data, it is imperative to adopt them for vehicle complaint analysis. This research paper puts forth a method to analyze vehicle

Venkatesan, Prasanna, Raju, Vivek

Tailgate Stiffness Mitigation and Engineering Strategy for Y-to-Y Tailgate-Mounted Tail Lamp Integration

2026-26-04941/16/2026

The tailgate, as the rearmost vehicle opening, plays a pivotal role in defining the rear aesthetic theme while ensuring structural durability and maximizing luggage space. Contemporary automotive design trends highlight an increasing demand for Y-to-Y tailgate-mounted tail lamp configurations, which deliver a bold and dynamic visual appeal. Enhanced by animated lighting features, these designs cater to the preferences of Gen Z customers, becoming a decisive factor in purchasing decisions. However, integrating these complex tail lamp structures introduces significant engineering challenges, including increased X-dimension volume, reduced design space, and intricate mounting schemes constrained by stamping limitations. These factors necessitate the development of innovative joinery strategies and structural definitions to maintain durability targets, including achieving 25,000–30,000 slam cycles without failure, while preserving luggage space. This paper explores a comprehensive approach

Beryl, Joshua, Mohanty, Abhinab, Unadkat, Siddharth, Selvan, Veera

Tolerances Titanium and Titanium Alloy Extruded Bars, Rods, and Shapes

AMS2245D (Current)

12/9/2025

This specification covers established manufacturing tolerances applicable to titanium and titanium alloy extruded bars, rods, and shapes. These tolerances apply to all conditions, unless otherwise noted. The term "excl" applies only to the higher figure of the specified range.

AMS G Titanium and Refractory Metals Committee

Cloths, Cleaning, For Aircraft Primary and Secondary Structural Surfaces

AMS3819E (Current)

12/9/2025

This specification covers woven, nonwoven, and knit absorbent materials supplied either as dry cloths or presaturated cloths for solvent cleaning process applications.

AMS G9 Aerospace Sealing Committee

AMS120425-1

AMS120425-00000000000000000000001 (Current)

12/4/2025

AMS120425-1

A-10 Aircraft Oxygen Equipment Committee

AIR120425-1

AIR120425-1 (Current)

12/4/2025

AIR120425-1

A-10 Aircraft Oxygen Equipment Committee

Guidelines for Repair Process Evaluation of Fiber Reinforced Composite Bonded Structure

AIR6292 (Current)

11/26/2025

The SAE Aerospace Information Report (AIR) is intended to be used as a process verification guide for evaluating implementation of key factors in bonded repair of fiber reinforced composite structure in a repair shop environment. The guide will be used in conjunction with a regulatory approved and substantiated repair, and is intended to promote consistency and reliability.

AMS CACRC Commercial Aircraft Composite Repair Committee

Guidelines for Repair Process Evaluation of Aluminum Bonded Structure

AIR6291A (Current)

11/26/2025

This SAE Aerospace Information Report (AIR) is intended to be used as a process verification guide for evaluating implementation of key factors in repair of metal bond parts or assemblies in a repair shop environment. This guide is to be used in conjunction with a regulatory approved and substantiated repair, and is intended to promote consistency and reliability.

AMS CACRC Commercial Aircraft Composite Repair Committee

Steel, Bars, Forgings, and Rings 0.95Cr - 0.20Mo (0.28 - 0.33C) (SAE 4130)

AMS6370S (Current)

11/25/2025

This specification covers an aircraft-quality, low-alloy steel in the form of bars, forgings, flash welded rings, and stock for forging or flash welded rings.

AMS E Carbon and Low Alloy Steels Committee

Steel Bars, Forgings, and Tubing 1.8Ni - 0.25Mo (0.38 - 0.43C) (4640)

AMS6312L (Current)

11/25/2025

This specification covers an aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock.

AMS E Carbon and Low Alloy Steels Committee

Steel, Bars, Forgings, and Tubing 0.50Cr - 0.55Ni - 0.20Mo (0.18 - 0.23C) (SAE 8620) Vacuum Arc or Electroslag Remelted

AMS6277K (Current)

11/25/2025

This specification covers a premium aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock.

AMS E Carbon and Low Alloy Steels Committee

Nickel Alloy, Corrosion and Heat-Resistant, Bars, Forgings, and Rings, 60Ni - 22Cr - 2.0Mo - 14W - 0.35Al - 0.03La, Solution Heat Treated

AMS5891D (Historical)

11/25/2025

This specification covers a corrosion and heat-resistant nickel alloy in the form of bars, forgings, flash welded rings, and stock for forging, flash welded rings, or heading.