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.

AMS F Corrosion Heat Resistant Alloys Committee

Nickel Alloy, Corrosion and Heat-Resistant, Bars, Wire, Forgings, and Rings 61Ni - 20.5Cr - 8.5Mo - 3.4Cb(Nb) - 1.3Ti - 5.0Fe Consumable Electrode or Vacuum Induction Melted Solution Heat Treated

AMS5854D (Current)

11/25/2025

This specification covers a corrosion and heat-resistant nickel alloy in the form of bars, wire, forgings, flash welded rings, and extrusions 4 inches (102 mm) and under in nominal diameter or least distance between parallel sides, and stock for forging or flash welded rings.

AMS F Corrosion Heat Resistant Alloys Committee

Iron Alloy, Corrosion and Heat-Resistant, Welding Wire, 31Fe - 21Cr - 20Ni - 20Co - 3.0Mo - 2.5W - 1.0Cb - 0.15N, Annealed

AMS5794G (Current)

11/25/2025

This specification covers a corrosion and heat-resistant iron alloy in the form of welding wire.

AMS F Corrosion Heat Resistant Alloys Committee

Steel, Corrosion and Heat-Resistant, Welding Wire 19Cr - 12.5Ni - 2.5Mo

AMS5696F (Current)

11/25/2025

This specification covers a corrosion and heat-resistant steel in the form of welding wire.

AMS F Corrosion Heat Resistant Alloys Committee

Steel, Corrosion-Resistant, Bars, Wire, Forgings, Mechanical Tubing, and Rings 16Cr - 4.0Ni - 0.30Cb - 4.0Cu Solution Heat Treated, Precipitation Hardenable Consumable Electrode Remelted

AMS5622H (Current)

11/25/2025

This specification covers a premium aircraft-quality corrosion-resistant steel in the form of bars, wire, forgings, mechanical tubing, flash welded rings up to 8.0 inches (203 mm) in diameter or least distance between parallel sides in the solution heat treated condition (see 8.4), and stock of any size for forging, flash welded rings, or heading (see 8.8).

AMS F Corrosion Heat Resistant Alloys Committee

Electron-Beam Welding For Fatigue Critical Applications

AMS2680D (Current)

09/30/2025

This specification defines the procedures and requirements for joining metals and alloys using the electron beam welding process.

AMS B Finishes Processes and Fluids Committee

Prediction Method of Strength Robustness Affected by Arc Welding Sectional Dimensions

2024-32-003804/18/2025

The arc welding process is essential for motorcycle frames, which are difficult to form in one piece because of their complex shapes, because a single frame has dozens of joints. Many of the damaged parts of the frames under development are from welds. Predicting the strength of welds with high reliability is important to ensure that development proceeds without any rework. In developing frames, CAE is utilized to build up strength before prototyping. Detailed weld shapes are not applicable to FE models of frames because weld shapes vary widely depending on welding conditions. Even if CAE is performed on such an FE model and the evaluation criteria are satisfied, the model may fail in the actual vehicle, possibly due to the difference between CAE and actual weld bead geometry. Therefore, we decided to study the extent to which the stresses in the joint vary with the variation of the weld bead geometry. Morphing, a FE modeling method and design of experiment method, was utilized to

Hada, Yusuke, Sugita, Hisayuki

Factors and Requirements for Adhesive Selection in Medical Devices, Part 1

TBMG-5214912/01/2024

The global medical device market is projected to reach a value of $656 billion USD by 2032 with a CAGR of 3 percent over the coming decade.1 The preceding decades of globalization and increased prosperity has provided advancement in both medical technology and access to advanced medical care for a greater proportion of the world’s population. Further, an aging population in North America, Europe, and parts of Asia will increase the need for healthcare-related services and medical devices in the coming decades. At present, the North America market continues to dominate the industry, accounting for approximately 43 percent of the market’s revenue share; however, markets in the Asia-Pacific region have the highest expected growth rates in the coming decades.1 Growth and innovation in the medical device market will be critical in the years to come.

Advancing Implantable Medical Device Reliability with Enhanced Laser Joining Technology

TBMG-5217712/01/2024

3D-PRINTING IMPACTS ON SYSTEMS ENGINEERING IN DEFENSE INDUSTRY

2024-01-352711/15/2024

ABSTRACT Today’s combat vehicle designs are largely constrained by traditional manufacturing processes, such as machining, welding, casting, and forging. Recent advancements in 3D-Printing technology offer tremendous potential to provide economical, optimized components by eliminating fundamental process limitations. The ability to re-design suitable components for 3D-printing has potential to significantly reduce cost, weight, and lead-time in a variety of Defense & Aerospace applications. 3D-printing will not completely replace traditional processes, but instead represents a new tool in our toolbox - from both a design and a manufacturing standpoint.

Deters, Jason

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

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

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

Effect of spot weld parameter on HAZ of advanced high strength steel joint.

2024-26-018701/16/2024

To meet different target of light-weighting, lower fuel economy, crash safety and emission requirement, advanced high strength steel (AHSS) is commonly used in automotive vehicles and has become popular now a days. AHSS material up-to 1500 MPa is commonly used for structural components and major reinforcement of automotive BIW. Manufacturing of AHSS material requires precise control of chemical composition, and subsequent rolling and heat treatment to get optimum combination of required phases In most of the AHSS material microstructure, martensite is present along with ferrite or other phases. Hot stamp steel with strength level 1500 MPa strength also have martensite phase in microstructure after press hardening. However during heating and cooling cycle in resistance spot welding, martensite phase tempering affects hardness at Heat Affected Zone (HAZ). Softness at HAZ zone lower downs shear and tensile strength of joint which impacts fatigue properties of the joint and energy

Jain, Vikas, Misal, Swapnali, Paliwal, Lokesh

Simulation of Crimping Process for Electrical Contacts to ensure Structural Integrity of Crimped Joint under Static Loads

2024-26-029101/16/2024

The use of electrical contacts in aerospace applications is crucial, particularly in connectors that transmit signal and power. Crimping is a widely preferred method for joining electrical contacts, as it provides a durable connection and can be easily formed. This process involves applying mechanical load to the contact, inducing permanent deformation in the barrel and wire to create a reliable joint with sufficient wire retention force. This study utilizes commercially available Abaqus software to simulate the crimping process using an explicit solver. The methodology developed for this study correlates FEA and testing for critical quality parameters such as structural integrity, mechanical strength, and joint filling percentage. A four-indenter crimping tool CAD model is utilized to form the permanent joint at the barrel-wire contact interfaces, with displacement boundary conditions applied to the jaws of the tool in accordance with MIL-C-22520/1B standard. The study identifies the

Aher, Ravi, More, Sandip Raghunath, Demarthon, Simon

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

Unique Optimization Approach of Axle Component and it’s Weld Life Improvement

2024-26-031601/16/2024

Axles are a prominent part of automotive design. Along with a power transmission and differential system, axles support a vehicle’s weight and road-load reactions. Axles carry different attachments such as brakes and suspensions using brackets. Welds play an important role in design and longevity of bracket assemblies. Welds can be susceptible to fractures caused by intrusions akin to cracks and/or discontinuities, compounded by stress concentration due to weld profile and welding processes. Additionally, the simultaneous optimization of both brackets and welds remains a challenge with limited available methods. While topography or shape optimization techniques can enhance bracket robustness by minimizing compliance as the objective, this approach might inadvertently elevate the likelihood of weld fracture if weld dimensions are not concurrently updated. In this endeavor, compliance is used to improve weld life without affecting bracket robustness by using the Vertex Morphing

Wagh, Pranav, Sutar, Mohan, Nilangekar, Abhijit

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

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

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

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

Why Cleanroom Assembly of Plastic Medical and Electronic Devices Requires Ultrasonic Welding Technology

TBMG-4646409/01/2022

For years, ultrasonic welding has been used in cleanrooms where plastic components are assembled to complete medical and electronic devices. That is unlikely to change. What is changing, however —rapidly — is the sophistication and complexity of these products and the level of precision and quality required to complete their assembly.

3D Welding Additive Manufacturing Humanoid for Spacecraft

2022-26-119305/26/2022

Space exploration is truly the most adventurous journey in the history of mankind. Satellites, space flights, and stations are deeper into the infinite expanse of the universe and these are susceptible to impact by orbital debris and meteoroids. In order to protect these machines from failures of their components and build new parts in space, we need an effective method to build 3D durable components in space. This paper discusses the usage of a LEMUR Robot for Additive Manufacturing using 3D Laser Welding. 3D laser welding uses a high concentration of energy to fuse the metal wires into a precise part that can withstand harsh conditions in the space environment. It offers high geometrical accuracy and material strengths. 3D welding uses laser metal fusion to build products layer by layer using the robotic arm attached to the Limbed Excursion Mechanical Utility Robot (LEMUR) which was originally designed to do repairs on the ISS. LEMUR has two legs and two arms which helps it to

Bhurat, Shryas, Yadav, Aashish, Shetty, Naman

Evolution and Redistribution of Residual Stress in Welded Plates During Fatigue Loading

2022-01-029803/29/2022

The presence of residual stresses affect the fatigue response of welded components. In the present study of a thick welded cantilever specimen, residual stresses were measured in an as-welded A36 steel sample and in a sample subjected to a short history of bending loads where substantial local plasticity is expected at the fatigue hot-spot weld toe. Extensive XRD measurements describe the residual stress state in a large region in front of the weld toe both in an untested as-welded sample and in a sample subjected to a short load history that generated an estimated 0.01 strain amplitude at the stress concentration zone at the weld toe. The results show that such a test will significantly alter the welding induced residual stresses. Fatigue life prediction methods need to be aware that such alterations are possible and incorporate the effects of such cyclic stress relaxation in life computations.

Pineault, James, Gales, Casey, Conle, Al

Sensitivity of Solid Element Spot Weld Modeling Methodology to Nugget Diameter

2022-01-094103/29/2022

A vehicle’s structure has more than 4000 spot welds, which can be considered as one of the main design criterion that affects the general stiffness as well as the durability of an automobile. Considering the essential role of finite element based simulations of the spot welded structures on the design phases of vehicle development, accuracy of analyses can be considered as one of the main concerns to meet the design objectives. This study examines the sensitivity of solid element spot weld modeling technology to nugget diameter. Comparative stress and multi-axial low cycle fatigue analyses are conducted for the inspection of the effect of weld diameter on solid element spot weld simulations. Displacement contours as well as local stress profiles at the vicinity of the spot welds are examined to evaluate the effect of nugget diameter on general stiffness and safety. Multi-axial low cycle fatigue analyses are conducted for the specimens composed of U-profiles, and different thickness

Duran, Ertuğrul Tolga

Development of an electric vehicle battery module laser welding process using SYSWELD and validation by test data

2022-01-037603/29/2022

With lightweight design in modern electric vehicles to achieve high energy efficiency, high strength and thin materials are widely adopted. For battery modules, 5000 and 6000 aluminum are typically utilized as a structural material with a thickness range between 1 to 5 mm. Laser welding is one of the most optimum welding tools for joining such a thin material due to its unique advantages, e.g., high welding speed, high accuracy, high energy yet the smallest heat affect zone, etc. This paper aims to develop an FE modeling procedure using SYSWELD to simulate the laser welding process used in electric vehicle battery module manufacturing. A sequentially-coupled thermo-mechanical analysis procedure is developed based on the welding processes for 6063 T6 aluminum alloys and the dissimilar joint between 6063 T6 and 5083 aluminum alloys. Different heat source models for laser welding are studies and compared. The effectiveness of the developed modeling procedure is confirmed by a large number

Song, Shaopin, JIANG, Weiran, Ding, Peiran

Manufacturing and Joining Considerations for Upper Body Structures Made in Ultra-High Strength 7075 Aluminium Alloys

2022-01-028403/29/2022

To date ultra-high strength aluminium alloys, such as AA7075, were used predominantly in aerospace industry where high cost and manufacturing challenges can be forgiven due to high value lightweighting potential of the material. This made the aerospace manufacturing techniques inaccessible to mainstream automotive industry. HFQ technology was developed to enable low cost high volume manufacture of high and ultra-high strength aluminium alloys opening up new lightweighting opportunities for automotive industry. The remining challenge was to develop and prove out a reliable joining technology for 7XXX series alloys. This paper discusses the linking of the HFQ manufacturing considerations, SPR joining and vehicle body thermal treatment required to process 7XXX made safety cell for EV vehicles.

Szegda, Damian

Prediction of Crash Performance of Adhesively Bonded Vehicle Front Rails

2022-01-105103/29/2022

Adhesive bonding provides a versatile strategy for joining metallic as well as non-metallic substrates, and also offers the functionality for joining dissimilar materials. For problems of elastic behavior and small strains in vehicle unibody structures such as designing for NVH (Noise, Vibration and Harshness), adhesive bonding of sheet metal parts along flanges provides enhanced stiffening of body and improved acoustics due to sealing of openings between flanges. However, due to the brittle nature of adhesives, they remain susceptible to failure under impact loading conditions which can cause crumpling of sheet metal parts resulting in plasticity and large strains. The viability of structural adhesives as a sole or predominant mode of joining stamped sheet metal panels into closed hollow sections such as hat sections thus remains suspect and requires further investigation. The mechanical behavior of adhesives tends to be significantly different as compared to ductile and isotropic

Ramachandra, Sanketh, Deb, Dr. Anindya, Chou, Clifford

Mechanical and microstructural behaviour of friction stir welded Al6061/Cr2O3 metal matrix composite.

2021-28-022410/01/2021

Aluminium metal matrix composite are widely used in various field like aerospace, marine and automobile application. The application of composites necessitates joining process and its difficult due to different materials. To address the considering difficulties the present study is, Cr2O3 was reinforced in Al 6061 matrix in 2% to 6% in the incremental step of 2%. The stir casting technique was used to fabricate the composites with 300rpm stirring speed and the stirring time duration was 3min throughout the fabrication process. The PCBN tool is used for prepared friction stir welded (FSW) joints and tool having 6.7mm pin diameter and 6mm pin height. The fabrication process is conducted by 1000rpm tool rotational speed and 25mm/min welding speed. The atmospheric and underwater environmental conditions was preferred to perform friction stir welding. The mechanical properties of the joint, such as tensile strength (ASTM E8), hardness (ASTM E18) and impact strength (ASTM E23) are

K, Senthilraj, Govindasamy, Rajamurugan, Krishnasamy, Prabu, Uday, KN

Parametric Optimization of Friction Stir Welded AA2024 using Regression Methods

2021-28-022310/01/2021

In this study, a model to optimize the friction stir welding parameters which were rotational speed, welding speed, axial force, tool pin profile, and tool material was established. The target of any design is to maximize the welded properties either to get the base metal properties or higher than that. The model constructed is the result of various regression methods which are quantified for adequacy. In this model, we have taken three levels of varying shoulder diameters, rotation speed, welding speed, tilting angles. A mathematical model is developed for the effect of four process parameters at three levels using response surface methodology (RSM). Analysis of variance (ANOVA) technique is used to check the adequacy of the developed mathematical model. The experimental and predicted values of the mechanical properties are correlated.

Ramasamy, Madesh, Kesavan, Gokul Kumar, Settu, Nandhakumar, Subramanian, Arun Prakash, Naiju, CD

Impact of weld fixture clamp force variation on dimensional integrity in low volume Body-in-White build

2021-28-021610/01/2021

Body in White (BIW) is an assembly of multiple sheet metal components. The BIW is the major contributor to the dimensional and structural integrity of an automobile. The accuracy and precision of the BIW is influenced by multiple factors involved in the manufacturing lifecycle of the BIW. Weld fixtures are the tools used for accurately locating and holding sheet metal components during joining. The primary motive of the locating and holding strategy is to arrest all degrees of freedom of a component. Geometric repeatability of the components is also of high importance. Component location is universally achieved by standardized locator pins and mylars that maintain the Principal Location Points (PLP) and Master Control Patches (MCP). In Low volume BIW build employs non-automated clamping methodologies in general, using manual clamps or toggle clamps. This paper studied the dimensional variation of sheet metal assemblies with variation in clamping forces in manual non-automated clamping

voppuru, Naga Sheshank Reddy, Selvam, Ganesan, Kannan, Muniya Gounder, Baskaran, V, Thiruppathi, R

An alternate CED process for low volume BIW manufacturing with single stage vertical dipping

2021-28-022710/01/2021

Body in White (BIW) is a major assembly in an automobile. It is made of sheet metal components that are welded together by Resistance spot welding. Assembled BIWs are put through an anti-corrosion process called Cathodic Electrodeposition (CED) and baked to set the CED coat. CED process has an elaborate sequence of rinse cycles and coat cycles. Single stage dipping stations are used for coating large volumes of smaller components. The high-cost multi-stage setup is a commonly used process in large scale BIW manufacturing systems. In the context of small-scale batch production or prototype builds, the extensive setup is not viable. This paper studied the feasibility of CED coating large BIWs in a single stage setup. Multiple process modifications explored to establish single stage setup for BIW coating. Process capability and effectiveness of utilization was studied. The results were analyzed, and the comprehensive process chain was concluded and discussed for implementation.

B, Sivasankar, Selvam, Ganesan, Kannan, Muniya Gounder, voppuru, Naga Sheshank Reddy, Thiruppathi, R

An experimental investigation on hot cracking and properties of TIG welded AA2014 alloy using continuous current and pulsed current

2021-28-026210/01/2021

AA2014 Aluminum alloys are most widely used for automobile and aerospace structures where specific strength is important. Hot cracking is a major problem while welding these alloys. In the present investigation, the metallurgical studies, viz, hot cracking sensitivity, microstructure and the mechanical properties, viz, hardness and tensile strength of the 4 mm thickness AA2014 aluminum alloy were studied using two different methods. The first method involves TIG (Tungsten Inert Gas) welding with continuous current process and the second method involves TIG welding with pulsed current process. In the both the process commercial argon pure gas was used as a shielding gas. The results showed that hot cracking sensitivity was decreased when the specimen was welded using pulsed current process compared to continuous current process. Similarly, the specimen was welded with pulsed current process showed improved mechanical properties compared to continuous current process because of low heat

Kaliyaperumal, Balasubramanian, R, Soundararajan, Rengaraj, Jeyakumar, Rangasamy, Ramamoorthi

Effect of Welding Consumables on Static and Dynamic Properties of Representative Welded Joints for Chassis Structure

2021-26-025909/22/2021

Automotive suspension system forms the basis for the design of vehicle with durability, reliability and NVH requirements. The automotive suspension systems are exposed to dynamic and static loads which in turn demands the highest integrity and performance against fatigue based metallic degradation. The current focus in automotive industry is to reduce the weight of the automotive parts and components without compromising with its static and dynamic mechanical properties. This weight reduction imparts fuel efficiency with added advantages. High-strength low alloy steel (HSLA) offers optimum combination of mechanical properties. Furthermore, welding processes offer design flexibility to achieve robust and lightweight designs with high strength steels. However, welding process has to be established to get optimum benefits of high strength steels with minimal adverse effects and deterioration of the static and dynamic mechanical properties of the weldments. In current work, effect of

Chauhan, Shiv, Varatharajan, Senthilkumaran, Shende, Deodatta

Strength Evaluation and Validation of Structural Joints.

2021-26-031509/22/2021

Many methods have been developed to evaluate the fatigue life of structures when the its joints are as per ideal case. But if the joints are loosening, it leads to increase in loading on the other members which causes failures. Most commonly in commercial vehicle segment welding joint & Bolting joints are most popular ones. It is very easy to find out bolts strength & loosening effect in static conditions. But when vehicle is moving (i.e. dynamic condition), same method cannot be used. For this we have developed methodology to predict the bolts loosening in dynamic condition using vibration data. Similarly, loading may differ on the structural members if the welds are failing in dynamic conditions. To overcome this problem, in our organization we have a solution. Of course to simulate welding failures fatigue analysis is mandatory. We are using notch-stress approach for evaluating the welding strength of the joint. This method does not need weld material data instead it increases the

Desai, Ankit Desai, Telukala, Haricharan, Jadhav, Santosh, Kurna, Srinivas

Characterization of Laser brazed joints Vis a Vis conventional BIW joining methods

2021-26-044709/22/2021

In recent years, there has been a rapid growing demand for laser brazing in the transportation industry for automotive-Body in White (BIW) steel sheet assembly. Implementation of laser brazing is aimed primarily to improve productivity, quality of joints and cost. Laser brazing works by filling the opening amongst two substrates by melting the filler wire with the help of laser beam (used as a heat source), whereas in conventional resistance spot welding, contacting metal surface points are joined by the heat obtained from resistance to electric current. Body in White (BIW) is essentially a welded metal structure which is meant to provide durability and crashworthiness to the vehicle and is conventionally assembled using resistance spot welding process. The BIW structure comprises of various steel grades having varying thicknesses, composition, microstructure and mechanical properties. Laser brazing as a joining method was introduced as an alternative to resistance spot welding for

Kumar, Animesh, Hatwalne, Mrunal, Ponkshe, Shripadraj, Misal, Swapnali

SAE TOMORROW TODAY: BMW Geniuses: Revving Up the Customer Experience

1315808/13/2021

At BMW Centers all over the world, product experts are a customer's new co-pilot. BMW Geniuses work to bridge the gap between complex engineering and the consumer experience not only to make more sales, but to create a loyal and more educated user base. BMW Genius Manager and "Chief Happiness Officer" Johnny Mizik from A&L Motor Sales joins the podcast to share the ins and outs of the new BMW shopping experience.

Hineman, Marcie

Flux, Aluminum Brazing For Torch or Furnace Brazing

AMS3412F (Current)

08/09/2021

This specification covers the requirements for an aluminum brazing flux in the form of powder or paste.

AMS B Finishes Processes and Fluids Committee

SAE TOMORROW TODAY: Soaking Up the Sun: America's First Solar-Powered Town

1315607/29/2021

Welcome to Babcock Ranch: the hometown of the future. Powered entirely by 700,000 solar panels across 840 acres of land in sunny Florida, Babcock Ranch is an innovative town that combines everything Americana with the technologies of tomorrow: electric-powered ice cream trucks, city-wide WiFi, expansive public green spaces, and the comfort of being part of a community. Syd Kitson, Chairman and CEO of Kitson & Partners - the founders of Babcock Ranch - joined us to share how he turned his vision for the future into reality - while making it economically viable along the way.

Hineman, Marcie

Assembly and Soldering Criteria for High Quality/High Reliability Soldering Wire and Cable Termination in Aerospace Vehicles

AS4461D (Current)

07/23/2021

This standard is applicable to manual soldering and machine soldering processes utilizing controlled soldering devices, for electrical connections for wiring and cabling used in aerospace vehicles. Description of a component or device herein is not to be construed as authorizing the use of the component or device.

AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install

Assembly and Soldering Criteria for High Quality/High Reliability Soldering Wire and Cable Termination in Aerospace Vehicles

AS4461D-TEST-REC (Historical)07/23/2021

AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install

SAE TOMORROW TODAY: Qualcomm is Changing the World with C-V2X Technology

1315207/06/2021

Just in time for the rollout of 5G, Qualcomm is connecting vehicles to networks, the cloud, other vehicles, pedestrians and more through C-V2X technology. Jim Misener, Senior Director of Product Management, Automotive, joins us to dig into how this technology is improving autonomy and safety. Misener, a pioneer in vehicle-highway automation and vehicle safety communication, also serves as SAE's C-V2X Technical Committee Chair. His commitment to innovation and STEM is apparent through Qualcomm's three-year commitment to provide experiential, project-based STEM learning to children through the SAE Foundation. Read about Qualcomm's STEM education investment to learn more about how you can invest in young minds and make a difference. Volunteer, donate or become a corporate partner and inspire the next generation of innovators through the SAE Foundation.

Hineman, Marcie

SAE TOMORROW TODAY: PennDOT Staying Ahead of Transportation Transformation

1315006/18/2021

No matter where industry goes - electric, automated, drones - PennDOT's Mark Kopko, Director of Transformational Technology, and his team are leveraging relationships with Pennsylvania's leading change-makers to educate, promote safety and develop policy that keeps the state on the forefront of technology. Tune in to hear PennDOT's strategy for setting the tone as the DOT of the future. Pennsylvania's rich experience in getting autonomous vehicles on the road offers great lessons. PennDOT shares this knowledge and so much more about the transformation of U.S. roadways through the PA AV Summit Series. Join the conversations to learn where the technology is going and hear from the partners, state leaders and universities that are making it happen. SAE is a proud sponsor of the 2021 series.

Hineman, Marcie

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