Browse Topic: Joining

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Prediction Method of Strength Robustness Affected by Arc Welding Sectional Dimensions2024-32-003804/18/2025
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
Technical Paper
Advancing Implantable Medical Device Reliability with Enhanced Laser Joining TechnologyTBMG-5217712/01/2024
Magazine Article
3D-PRINTING IMPACTS ON SYSTEMS ENGINEERING IN DEFENSE INDUSTRY2024-01-352711/15/2024
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
Technical Paper
A Comparison of Wire Bonding vs. Spot Welding vs. Soldering in the Prevention of Thermal Runaway in a Battery Pack2024-26-010901/16/2024
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
Technical Paper
Evaluation of interface microstructure and bonding strength for dissimilar rotary friction welding of E46 and AA6061-T62024-26-019501/16/2024
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
Technical Paper
Review on Laser welding of High Strength Aluminium alloy for Automotive Applications2024-26-019301/16/2024
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
Technical Paper
Damage Tolerant Fracture Assessment of Cracks in Non-Standard Geometries Under Static and Fatigue Loading2024-26-027601/16/2024
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
Technical Paper
Lightweight potential and crash performance of friction stir welded Tailored Blanks2023-01-122006/26/2023
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
Technical Paper
Why Cleanroom Assembly of Plastic Medical and Electronic Devices Requires Ultrasonic Welding TechnologyTBMG-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.
Magazine Article
3D Welding Additive Manufacturing Humanoid for Spacecraft2022-26-119305/26/2022
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
Technical Paper
Development of an electric vehicle battery module laser welding process using SYSWELD and validation by test data2022-01-037603/29/2022
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
Technical Paper
Evolution and Redistribution of Residual Stress in Welded Plates During Fatigue Loading2022-01-029803/29/2022
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
Technical Paper
Manufacturing and Joining Considerations for Upper Body Structures Made in Ultra-High Strength 7075 Aluminium Alloys2022-01-028403/29/2022
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
Technical Paper
Sensitivity of Solid Element Spot Weld Modeling Methodology to Nugget Diameter2022-01-094103/29/2022
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
Technical Paper
Prediction of Crash Performance of Adhesively Bonded Vehicle Front Rails2022-01-105103/29/2022
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
Technical Paper
Impact of weld fixture clamp force variation on dimensional integrity in low volume Body-in-White build2021-28-021610/01/2021
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
Technical Paper
Parametric Optimization of Friction Stir Welded AA2024 using Regression Methods2021-28-022310/01/2021
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
Technical Paper
An alternate CED process for low volume BIW manufacturing with single stage vertical dipping2021-28-022710/01/2021
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
Technical Paper
An experimental investigation on hot cracking and properties of TIG welded AA2014 alloy using continuous current and pulsed current2021-28-026210/01/2021
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
Technical Paper
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
Technical Paper
Characterization of Laser brazed joints Vis a Vis conventional BIW joining methods2021-26-044709/22/2021
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
Technical Paper
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
Technical Paper
Effect of Welding Consumables on Static and Dynamic Properties of Representative Welded Joints for Chassis Structure2021-26-025909/22/2021
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
Technical Paper
SAE TOMORROW TODAY: BMW Geniuses: Revving Up the Customer Experience1315808/13/2021
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
Podcast
Flux, Aluminum Brazing For Torch or Furnace BrazingAMS3412F (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
Material Specification
SAE TOMORROW TODAY: Soaking Up the Sun: America's First Solar-Powered Town1315607/29/2021
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
Podcast
Assembly and Soldering Criteria for High Quality/High Reliability Soldering Wire and Cable Termination in Aerospace VehiclesAS4461D-TEST-REC (Historical)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
Technical Standard
Assembly and Soldering Criteria for High Quality/High Reliability Soldering Wire and Cable Termination in Aerospace VehiclesAS4461D (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
Technical Standard
SAE TOMORROW TODAY: Qualcomm is Changing the World with C-V2X Technology1315207/06/2021
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
Podcast
SAE TOMORROW TODAY: PennDOT Staying Ahead of Transportation Transformation1315006/18/2021
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
Podcast
Steel, Welding Wire 0.50Cr - 0.55Ni - 0.20Mo (0.18 - 0.23C) (SAE 8620) Vacuum Melted, Environment Controlled PackagingAMS6375E (Current)04/06/2021
This specification covers a low-alloy steel in the form of welding wire. Type 2 - copper coated wire was removed from this document (see 8.5).
AMS E Carbon and Low Alloy Steels Committee
Material Specification
Numerical Simulation of Aircraft Assembly Process with Presence of Sealant2021-01-000103/02/2021
Sealant is applied between joined aircraft parts in the final stage of the assembly, before installation of permanent fasteners. In this paper a novel approach for aircraft assembly simulation is suggested, which allows to resolve the transient interaction between parts and sealant in the course of airframe assembly process. The simulation incorporates such phenomena as compliance of parts, contact interaction between them and fluidity of sealant with presence of free surface. The approach based on fluid-structure interaction techniques consists of two basic steps: at the first one the pressure of sealant is found after corresponding fluid dynamics problem is solved and at the second the displacements of parts and sealant are calculated through the solving of contact problem. Iterations between structural and fluid dynamics solvers are performed to achieve convergence. The developed approach is demonstrated on example of joining of two test aircraft panels. The viscosity of sealant was
Eliseev, Artem, Lupuleac, Sergey, Grigor'ev, Boris, Shinder, Julia, Bouriquet, Jacques
Journal Article
SAE TOMORROW TODAY: Micromobility for the Masses With Swiftmile1292802/05/2021
What if your commute to work was fun, fast and convenient? Swiftmile is answering the call, building the infrastructures that cities and businesses need to enable large scale adoption of micromobility. On this episode, Keith Moravick, CTO and VP of Engineering and Product at Swiftmile, joins us to share how his experience researching and riding light electric vehicles (LEVs) enables continuous innovation in the world of electric and solar bikes, scooters and more. Swiftmile is making micromobility accessible and efficient across cities. From developing charging stations and racks for removing the clutter of scooters on streets to adding more transportation options in convenient urban areas, Swiftmile is meeting the needs of commuters, businesses and cities. Discover how "playing" with LEVs has led Keith and Swiftmile to lead the way, enabling micromobility accessibility for all.
Hineman, Marcie
Podcast
Steel, Welding Wire 0.65Si - 1.25Cr - 0.50Mo - 0.30V (0.28 - 0.33C) Vacuum Melted, Environment Controlled PackagingAMS6458K (Current)02/03/2021
This specification covers a low-alloy steel in the form of bare welding wire. Type 2 - copper coated wire was removed from this document (see 8.5).
AMS E Carbon and Low Alloy Steels Committee
Material Specification
Wafer-Scale Membrane Release ProcessTBMG-3847602/01/2021
Precise measurements utilizing sensitive instruments may require thermally managed detectors; therefore, thermal insulation of the detector is essential to its performance. To maintain critical signal-to-noise ratio, there is a need for larger thermal isolation structures. Due to high detector filling fraction limits, these isolation structures may be thinner, less mechanically robust, and more prone to breakage during fabrication.
Magazine Article
Lap Shear Test for Automotive-Type Adhesives for Fiber Reinforced Plastic (FRP) BondingJ1525_202101 (Current)01/07/2021
This SAE Recommended Practice describes a lap shear test method for use in measuring the bonding characteristics of automotive-type adhesives for joining fiber reinforced plastics (FRPs) to themselves and to metals.
Materials, Processes and Parts Council
Recommended Practice
Coach Joint Fracture TestJ1863_202101 (Current)01/07/2021
This SAE Recommended Practice defines a procedure for determining the cleavage strength of an adhesive used for bonding automotive oily metal substrates.
Materials, Processes and Parts Council
Recommended Practice
Surface Match Verification Method for Pressure Sensitive Adhesively Attached ComponentsJ2215_202101 (Current)01/07/2021
This SAE Recommended Practice applies to evaluation of the conformance match condition existing between two surfaces. Evaluation of this conformance may be especially useful in bonded applications although it may also have relevance to bolted adjacent surface joint conditions. Since good bonding surface conformity is necessary for providing optimal bond performance with pressure sensitive adhesives, the purpose of this document is to provide a method of evaluating the conformance match of the mating surfaces. This document is intended as a guide toward standard practice but may be subject to frequent change to keep pace with experience and technical advances. This should be kept in mind when considering the use of this document. Tool types, materials, application tools, and component contact area evaluation methods are included as part of this document. In most cases a visual evaluation of contact performance may be satisfactory; however, for greater accuracy a measurement tool may be
Materials, Processes and Parts Council
Recommended Practice
Overlap Shear Test for Automotive Type Sealant for Stationary Glass BondingJ1529_202101 (Current)01/07/2021
This SAE Recommended Practice defines a procedure for the construction and testing of glass to metal lap shears for determining shear strength of sealant adhesives for automotive stationary glass bonding. This procedure can also be used for fiber reinforced plastic (FRP) when used in place of metal.
Materials, Processes and Parts Council
Recommended Practice
Will Travel Ever Be the Same Again: Exploring the Post-COVID World1292012/10/2020
What's next after the pandemic? Many industries have been asking that question and during SAE's Roundtable Series on the impacts of COVID-19 some companies are searching for the answer. This week we were joined by guest co-hosts, Dr. Sven Beiker, External Advisor at SAE International, and Sven Taubert, Head of Corporate Foresight & Market Intelligence at Lufthansa Technik, to discuss their SAE roundtable conversation and look at ways that can continue to support members as they tackle the challenges of tomorrow. Sven Taubert shared his perspective on what it means to plan for a pandemic as an airline and addressed the pressing question, "Will travel ever be the same?" Discover why Lufthansa Technik is in the business of trust and what consolidations are on the horizon for the aviation industry in response to the global pandemic.
Hineman, Marcie
Podcast
SAE TOMORROW TODAY: Will Travel Ever Be the Same Again: Exploring the Post-COVID World1291712/10/2020
What's next after the pandemic? Many industries have been asking that question and during SAE's Roundtable Series on the impacts of COVID-19 some companies are searching for the answer. This week we were joined by guest co-hosts, Dr. Sven Beiker, External Advisor at SAE International, and Sven Taubert, Head of Corporate Foresight & Market Intelligence at Lufthansa Technik, to discuss their SAE roundtable conversation and look at ways that can continue to support members as they tackle the challenges of tomorrow. Sven Taubert shared his perspective on what it means to plan for a pandemic as an airline and addressed the pressing question, "Will travel ever be the same?" Discover why Lufthansa Technik is in the business of trust and what consolidations are on the horizon for the aviation industry in response to the global pandemic.
Hineman, Marcie
Podcast
LEAD-FREE SOLDER VALIDATION TEST PLANUSCAR40-2 (Current)11/19/2020
This guideline is applicable to existing lead solder production products that will change to lead-free solder processes to meet the ELV Directive 2000/53/EC Annex II, exemption 8B requirements. This guideline is applicable to similar products used by multiple OEM's that have the same manufacturing processes / equipment. The intent is to streamline the supplier’s environmental testing via common qualification to reduce timing, quantities, and costs.
USCAR
Specification
SAE TOMORROW TODAY: Safety at the Forefront of Mobility1291210/22/2020
Jennifer Morrison, Manager of Vehicle Safety Compliance, Mazda North America joins host Grayson Brulte on SAE Tomorrow Today to discuss all of the facets of safety in the world of mobility. Jennifer kicks things off by recounting her emotional experiences investigating highway crashes while at the National Transportation Safety Board. She then digs into why safety must be a foundational element for every mobility company, the importance of standardizing safety features in vehicles, training dealers to inform car buyers on proper usage of safety features, how schools and groups can educate themselves on their transportation service providers, and how autonomous mobility will shift our future driving habits.
Hineman, Marcie
Podcast
SAE TOMORROW TODAY: One Day Kids Will Play in the Streets Again1290709/17/2020
What will cities look like as we come out of the COVID-19 pandemic? Ashwini Chhabra, Co-Founder & Principal of Electric Avenue, joins us this week to offer his take on how trends that have emerged during the shutdown can, and likely will, transfer as cities begin to open back up. First, we talk about Ashwini's background that has transitioned from the financial service sector to the New York City education system to the urban transportation space, and how he has applied private sector thinking to public sector problems. With Ashwini's background in education, the conversation looks at how schools in New York are taking advantage of available outside space and how prioritizing public space will play an important role in city planning. Ashwini discusses the importance of planning ahead to move people around in the ways they need to properly function the city by using all forms of transportation. The New York City subway system gets a long look as well with the need to rebuild confidence
Hineman, Marcie
Podcast
SAE TOMORROW TODAY: Great Things Take Time - VC's View on Technology1290308/21/2020
From building software companies to investing in new technologies, Jason Illian, Managing Director at Koch Disruptive Technologies, has seen both sides of the innovation spectrum. He joins the podcast this week to offer a venture capitalist's perspective on investing in disruptive technologies and sectors, how creating a level market playing field that enables the best technologies and companies to succeed benefits society as a whole, and the ways parents can create teachable moments to inspire kids for lifelong learnings. The conversation looks at the trends that are being accelerated due to the COVID-19 pandemic, from the education landscape to medical technologies to warehousing and logistics. Jason closes out the discussion by sharing the vision and focus for the future of Koch Disruptive Technologies and offering advice to burgeoning entrepreneurs who want to raise capital for the first time. Learn more about Koch Disruptive Technologies at https://www.kochind.com/companies/koch
Hineman, Marcie
Podcast
Steel, Bars, Forgings, and Rings 0.95Cr - 0.20Mo (0.28 - 0.33C) (SAE 4130)AMS6370R-TEST-REC (Historical)07/07/2020
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
Material Specification
Steel, Bars, Forgings, and Rings 0.95Cr - 0.20Mo (0.28 - 0.33C) (SAE 4130)AMS6370R (Current)07/07/2020
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
Material Specification
Process Development of Dissimilar Clinch Joints in Cross-Tension Specimens of AA5052 and TP-CFRP Sheets2020-01-022504/14/2020
This paper studied the process development of dissimilar clinch joints in cross-tension specimens of aluminum alloy 5052-H32 (AA5052-H32)/thermoplastic carbon fiber reinforced plastic (TP-CFRP) sheets. The AA5052-H32 and TP-CFRP sheets with a thickness of 1.6 mm were used. The important processing parameters for AA5052/TP-CFRP clinch joints, such as the punching load, heating mode, heating temperature, and die depth, were considered. The failure loads, failure modes, and metallographic micrographs of AA5052/TP-CFRP clinch joints were analyzed to determine an available processing parameter set for fatigue tests. Finally, the fatigue performance and failure mode of AA5052/TP-CFRP clinch joints were obtained.
Lin, Pai-Chen, Fang, Gavin, Lin, Chia-Wei, Ching, Yern Chee
Journal Article
Hybrid Forming - A Novel Manufacturing Technique for Metal-LFT Structural Parts2020-01-023504/14/2020
Hybrid structural parts combining aluminum or steel sheets with long glass fiber reinforced thermoplastics (LFT) offer a great opportunity to reduce component weight for automotive applications. But due to high manufacturing cost, metal-LFT hybrid components are still scarcely used in automotive large-scale production. Thus in this work a novel cost- and time efficient manufacturing process for simultaneous metal sheet forming and compression molding of long fiber reinforced thermoplastics to manufacture automotive lightweight components is presented. In this manufacturing process, which is referred to as “Hybrid forming”, a fiber reinforced thermoplastic melt is used as a forming medium in the manner of well-known hydroforming processes. After forming the metal sheet by polymer melt in combination with the rigid die, the melt solidifies and forms a local reinforcement structure in the hybrid component. Since the metal sheet is pre-coated with a bonding agent prior to the forming
Heidrich, Daniel, Kloska, Tobias, Fang, Xiangfan
Journal Article
Research on Joining High Pressure Die Casting Parts by Self-Pierce Riveting (SPR) using Ring-Groove Die Comparing to Heat Treatment Method2020-01-022204/14/2020
Nowadays, the increasing number of structural high pressure die casting (HPDC) aluminum parts need to be joined with high strength steel (HSS) parts in order to reduce the weight of vehicle for fuel-economy considerations. Self-Pierce Riveting (SPR) has become one of the strongest mechanical joining solutions used in automotive industry for the past several decades. Joining HPDC parts with HSS parts can potentially cause joint quality issues, such as joint button cracks, low corrosion resistance and low joint strength. The appropriate heat treatment will be suggested to improve SPR joint quality in terms of crack reduction. But the heat treatment can also result in the blister issue and extra time and cost consumption for HPDC parts. The relationship between the microstructure of HPDC material before and after heat treatment with the joint quality is going to be investigated and discussed for interpretation of cracks initiation and propagation during riveting. The SPR joint quality
Zhao, Xuzhe, Zhang, Jianyue, Chu, Yeou-li, Cheng, Patrick, Meng, Dean
Technical Paper
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