Browse Topic: Casting

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Effect of the Flow Forming Process on the Mechanical properties and Microstructure of GDC & LPDC cast aluminum alloy wheels.2026-26-02981/16/2026
Aluminum alloy wheels have become the preferred choice over steel wheels due to their lightweight nature, enhanced aesthetics, and contribution to improved fuel efficiency. Traditionally, these wheels are manufactured using methods such as Gravity Die Casting (GDC) [1] or Low Pressure Die Casting (LPDC) [2]. As vehicle dynamics engineers continue to increase tire sizes to optimize handling performance, the corresponding increase in wheel rim size and weight poses a challenge for maintaining low unsprung mass, which is critical for ride quality. To address this, weight reduction has become a priority. Flow forming [3,4], an advanced wheel production technique, offers a solution for reducing rim weight. This process employs high-pressure rollers to shape a metal disc into a wheel, specifically deforming the rim section while leaving the spoke and hub regions unaffected. By decreasing rim thickness, flow forming not only reduces overall wheel weight but also enhances strength and
Singh, Ram Krishnan, Medaboyina, HarshaVardhan, G K, Balaji, Gopalan, Vijaysankar, SUNDARAM, RAGHUPATHI, Paua, Ketan
Multi-Material Front Structures: A Pathway to Safer and More Sustainable Vehicle Design2026-26-04561/16/2026
Frontal crash structures play a vital role in occupant safety, but traditional designs often involve a trade-off between structural strength and weight efficiency. In the pursuit of safer and more sustainable mobility, this study explores a physics-based methodology that leverages the principle of dynamic equilibrium to guide the integration of dissimilar materials in front-end vehicle structures. Specifically, we examine a novel configuration wherein aluminum High pressure die cast (HPDC) is introduced in swan neck region of the front longitudinal member, while retaining steel in the frontal crush zone. This arrangement aims to redistribute crash loads and control deformation mechanisms, enabling improved energy absorption without compromising structural integrity. To evaluate the proposed strategy, a series of detailed finite element simulations were conducted using LS-DYNA, a widely adopted tool for vehicle crash analysis. The results reveal that the dynamic equilibrium approach
Revanth, Goshika, Bhagat, Milind, Joshi, Vikas, Mankhair, Abhijit, Sudarshan, B.Sudarshan, Kollipara, Jahanavi
Evaluating the Suitability of ADC12 for Sand Casting: Filling, Solidification, and Mechanical Properties2026-26-02961/16/2026
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 numerical approach to optimize the flow characteristics for the enhancement of casting soundness of Al 6061 alloy die-casting2026-26-02841/16/2026
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
Hard Anodic Coating of Magnesium AlloysAMS2466D (Current)12/9/2025
This specification covers the requirements for a hard anodic coating on magnesium alloys.
AMS B Finishes Processes and Fluids Committee
Aluminum Alloy, Castings 4.7Cu - 0.60Ag - 0.35Mn - 0.25Mg - 0.25Ti (B201.0-T7) Solution Heat Treated and Overaged AMS4242D (Current)12/9/2025
This specification covers an aluminum alloy in the form of castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Die Castings 8.5Si - 3.5Cu (A380.0-F) As Cast AMS4291K (Current)11/21/2025
This specification covers an aluminum alloy in the form of die castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Die Castings 9.5Si - 0.50Mg (360.0-F) As Cast AMS4290N (Current)11/21/2025
This specification covers an aluminum alloy in the form of die castings.
AMS D Nonferrous Alloys Committee
A review of warm forming for steels: History, Methodology and Emerging trends2025-01-88144/1/2025
Many manufacturing techniques and process modifications have been implemented over the years to improve the formability of sheet metals. Warm forming of sheet metals is one such established method. However, it is more commonly and successfully applied to aluminum grades. The reevaluation of less-used metal forming technologies, such as warm forming and sheet hydroforming for steel, is a response to the challenges posed by competitive processes like large castings and the geometry requirements of new BEV parts. By understanding the effects of elevated temperatures (below recrystallization temperatures) on different steel grades and the impact of various heating methodologies, the industry can adapt and optimize these proven techniques for modern applications. This paper is a comprehensive summary of the effect of elevated temperatures on various grades of steel. Different heating techniques, their cycle times and effects on final forming feasibility is contrasted. The effect of
Kella, Caroline, Wormald, Tom, Gatts, Joshua
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
Casting Equipment Engineering GuideB-ASM-0563/1/2024
Casting Equipment Engineering Guide is an essential resource covering engineering details of casting equipment, their design features, applications, capabilities, and selection guidelines. This book is written for mechanical engineers, practicing engineers, engineering students, and metallurgists specializing in casting technology.
Defect based fatigue life predictions for Aluminum Castings using Simulations2024-26-02891/16/2024
Aluminum casting parts generally have inherent internal defects such as porosity which lowers the fatigue strength of such castings. Accounting for such a fatigue strength reduction for Aluminum casted parts is the primary purpose of this paper. Authors have used Murakami et al [1] approach to calculate a ‘porosity correction factor’ for fatigue. The actual material S-N curve is modified using fatigue factors to account for the fatigue strength reduction due to presence of porosity. This approach was then validated on one of the fatigue failure cases on Aluminum casted housing. There was a close match between the test data and proposed approach for fatigue prediction. With this approach, engineers will be able to do fatigue predictions in presence of material defects like porosity with simple porosity correction factor, rather than using complex modeling of porosity in FEA or using detailed fracture mechanics methods. Engineers can also be able to provide acceptable levels of porosity
Kumar, Rohit, Gawture, Majnoo M
Importance of Casting Soundness in Aluminium parts for Laser Weld Quality2024-26-01911/16/2024
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
Tolerance Relief on Transmissions Castings for ProducibilityF-0078-2022-175695/10/2022
ABSTRACT
Gimbutis, Brad, Palmer, Griffin, Beardsley, Justin, Quinn,  Holly
Optimized Semi-Solid Slurry Aluminum Die Casting for HPDC Structural Components2022-01-02833/29/2022
Electric Vehicles (EV) are transforming the automobile industry by creating a renewed approach to propulsion through battery powered electric drive unit (EDU). Key to the success of the EV industry is vehicle drive range on a fully charged battery. That limit state is dependent on many factors, but one critical one is vehicle mass. Vehicle mass is a parasitic loss in energy consumption; and therefore, the mass of EV has been valued at much higher levels than for internal combustion engine vehicles. Therefore, finding opportunities for light weight options is crucial. In this paper, optimization method for aluminum semi-solid slurry die cast (SSD) for high pressure die casting (HPDC) will be discussed. A novel approach to slurry preparation, transfer, die operation, and post cast process was developed and was proven on structural components of EDU mounting system. 40% part mass saving was achieved in a study case compared to baseline conventional HPDC design. On average, it is
Jomaa, Sam, Risko, Frank, Xu, Yiwu, Liang, Xiaokang, Suchta, Wojciech, Quaggiotto, Michael
Microstructure Control with a Combined Metal Additive Manufacturing and Deformation Processing 2022-01-03233/29/2022
Direct metal additive manufacturing provides great flexibility in 3D shaping as compared with traditional manufacturing processes of metal casting, deformation followed by machining and joining for obtaining final production shape. On the other hand, it suffered from its dendric microstructure produced during solidification. This study reports the development of a new combined metal additive and deformation processes to take advantages and reduce/eliminate the drawback from individual process. There are many forms of direct metal deposition processes mainly categorized by the heating source and heat application method used. Similarly, there are also many deformation processes that can provide a wide range of applied stress, strain, strain rate and temperature, which ultimately determine the final microstructure and property of the product. One constraint for selection of deformation process is the need to provide local deformation to allow flexible 3D printing and forming. To
ELALEM, AHMED, Wu, Xin
Padded Self-Piercing Riveting (P-SPR) on magnesium high pressure die casting2022-01-02873/29/2022
As a mechanical joining technology well established on aluminum and steel, self-piercing riveting (SPR) is exploring its application on magnesium. The main issue with the development of magnesium SPR technology is the button cracking which is ascribed to magnesium’s limited slip systems in room temperature. To address the issue at room temperature, an innovative padded self-piercing riveting (P-SPR) process was developed to mitigate the cracks by integrating a disposable pad into the rivet setting process. An experiment was designed to join a piece of 2.0mm thick 6061-T6 aluminum to a piece of 3.2mm thick powder coated AM60B magnesium high pressure die casting (HPDC) under 3 different configurations including the conventional SPR process as a baseline, the conventional SPR process with an optimized die and the P-SPR process. Through the comparison on button surface, cross-section and joint strength, the P-SPR solution with a joint strength of 6.5kN protected both metal and powder
Liu, Yuchao (Chad), Wang, Gerry, Weiler, Jonathan
Sensor-controlled Friction Materials based on Liquid Friction Compounds, Chip-in-Pad Concept2021-01-129610/11/2021
In this paper, the concept of integrating thin-film piezo transducers into friction pads by using a liquid friction material compound (LIQFRIC® HP), which is capable of completely embedding the sensor surface and allowing for the force transfer due to a direct contact between sensor and friction material, is explained. The low thickness of the sensor allows for an excellent ratio of sensor volume / friction volume in the pad. The piezo transducer, besides being able to detect positive and negative pressure changes, can also be used via its EMI capability to allow measurements of changes in the shape (and therefore thickness) of the pad during and after testing. Measuring the pressure distribution, the wear and possible defect situations of the pad potentially opens up new means of friction pad- and brake operations or developments.
Milczarek, Roman Paul
Cast Aluminum Alloy Composite 4.6Cu - 3.4Ti - 1.4B - 0.75Ag - 0.27Mg (205.0/TiB2/3p-T7P) Investment Cast, Solution and Precipitation Heat TreatedAMS4471B (Historical)4/22/2021
This specification covers a dilute aluminum/TiB2 metal matrix composite in the form of investment castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Castings 5.0Si - 1.2Cu - 0.50Mg (355.0-T51) Precipitation Heat TreatedAMS4210M (Current)4/22/2021
This specification covers an aluminum alloy in the form of castings.
AMS D Nonferrous Alloys Committee
Application of Casting to Automotive ECU’s2021-01-01314/6/2021
Casting is the ability to let users transfer their favorite videos, music, movies, etc. from their phone to a chosen display. This functionality has become very popular these days, and to the user, it is as simple as clicking a button. This “simple” task is a complex system that requires various independent sources to communicate efficiently and effectively to produce a robust and reliable output. The sending and receiving devices are required to be on the same network - which involves reliable and secure connection. This allows the sending of the URL of the chosen feature to the server provider, which will then connect to the receiver embedded electronics where the authentication process that protects Digital Rights Management (DRM) is established.
Chmeiseh, Mustafa H., Kazensky, Dennis, Sengupta, Sankar
Utilizing Casting Technologies on Legacy PartF-0076-2020-1627910/5/2020
Sikorsky has developed a specification outlining the use of three casting technologies: simulation, additive manufacturing of the mold and low pressure casting. This specification has been used in the past on new development projects with positive results, reducing lead times and number of pours to produce a useable part. When the S-92 program needed to develop a second source for a casting, they worked with Magellan Aerospace to implement the specification. The project proceeded on time with all castings able to be used. Some elements of the specification were modified to work with a legacy part design, including the use of statistical process controls to reduce variability in crucible pouring.
Woodworth, Heather, Featheringham, Andrew
Rust Is Not a Must. Improvement of Discs Corrosion Resistance by Tuning of Grey Cast Iron Alloying Elements and Microstructure2020-01-162410/5/2020
The manuscript reports about the corrosion performance of a series of grey cast iron specimens including an increasing concentration of Aluminum as alloying element. An improved corrosion resistance for %Al >1%wt is demonstrated and a reasonable corrosion mechanism is proposed as well. Electrochemical techniques allow to calculate a particularly high corrosion potential (Ecorr) for the sample including 4%wt Al, equals to -572 mV vs. Saturated Calomel Electrode (SCE). The manuscript is aimed at demonstrating that the fine tuning of alloying elements in cast iron is a particularly effective method in order to improve its corrosion resistance, thus allowing the development of future disc-brake rotors with a prolonged operating life.
Bertasi, Federico, Dudzik, Bozena, Mancini, Alessandro, Bandiera, Marco, Biondo, Simone, Bonfanti, Andrea
Reducing Risk in 3D Printed Composite ToolingF-0076-2020-1628010/5/2020
For high end composite manufacturing in a rapid development environment, the long lead item is often the hard tooling, in particular the cure mold. A traditional metal mold takes in the neighborhood of four to nine months to design, fabricate and validate. With high temperature capable print materials, and larger and faster printers, Additive Manufacturing (AM) appears to have high potential in this area of advanced composites manufacturing. Sikorsky has used AM very successfully on a scale up to approximately 3'x3' and cure temperatures of 350°F. Though long-term durability is still to be determined; the materials, technologies, and techniques Sikorsky has employed for AM autoclave cure molds on this scale have consistently exceeded expectations. AM tools along the scale of main rotor blades could be leveraged to realize even more significant cost and schedule gains from AM autoclave tooling, and in this area, there are still more questions than answers when it comes to a dependable
Dunn, Eric
Metal Injection Molding Offers OEMs Edge and Safety with DisposablesTBMG-371176/1/2020
Medical instruments used in surgery today often require more elaborate features and added functionality than they did in the past, largely due to the growth in minimally invasive surgery. For this reason, greater attention to detail is critical in product design and development. To meet the demand for small, complex, lightweight surgical products, medical device original equipment manufacturers (OEMs) are increasingly opting for disposable surgical tools and product offerings, which provide flexible, off-the-shelf single-use sterile solutions to surgeons and hospitals.
Research on Joining High Pressure Die Casting Parts by Self-Pierce Riveting (SPR) using Ring-Groove Die Comparing to Heat Treatment Method2020-01-02224/14/2020
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
Method for Electrospinning Customizable NanofibersTBMG-363914/1/2020
Electrospinning uses electric fields to manipulate nanoscale and microscale fibers. The technique is well-developed but time-intensive and costly. A new method was developed to create customizable nanofibers for growing cell cultures that cuts time spent removing toxic solvents and chemicals.
Theoretical Modeling of the Mechanical Degradation of Polymer Composites due to Moisture/Water Absorption and Damage Progression2019-01-13763/19/2019
The moisture/water absorption and microvoids/cracks progression are two well-understood mechanisms that have significant degradation effects on the mechanical properties/behaviors of the polymer-based composites. To theoretically investigate the effects of above two mechanisms, we develop a simple fiber reinforced polymer composites model by employing the internal state variable (ISV) theory. The water content and the anisotropically distributed damage of the composites are considered as two ISVs (the water content is described by a scalar variable and the damage is defined as a second order tensor) whose histories are governed by two specific physically-based evolution equations. The proposed model can be easily cast into a general theoretical framework to capture more polymer composites behaviors such as viscoelasticity, viscoplasticity and the thermal effect. The results predicted by current model are in good agreement with the experimental data, which allows us to implement the
He, Ge, Liu, Yucheng
Effects of As-Cast Surface Conditions and Local Geometry on Plating Deposition2018-01-504511/14/2018
The inhomogeneity of casting microstructure can present many challenges to subsequent processing of castings such as electroplating. Specifically the surface microstructure and local topographic features have significant impact on the electroplating deposition thus the continuity of the plating films. The authors attempt to categorize the common casting surface microstructure features and correlate them to the electroplating characteristics such as conductivity and current density distribution, which in turn affect the plating deposition. Forming mechanisms of some of the most common casting surface microstructures that affect electroplating are discussed. Desirable casting surface microstructure for electroplating and the casting design and process practices to achieve it are proposed.
Huang, Yanjun, Ohta, Makoto, Pederson, Tara, Milligan, Orit (Baron)
COVER – ENGINE ACCESSORY DRIVE, SQUARE, 5.000 BOLT CIRCLE, AMS4490 (UNS M11910)AS3222D (Current)10/18/2018
E-25 General Standards for Aerospace and Propulsion Systems
COVER - ENGINE ACCESSORY DRIVE, SQUARE, 127.28 BC, METRIC AMS4424 (UNS M11630) OR AMS4484MA3454B (Current)9/17/2018
E-25 General Standards for Aerospace and Propulsion Systems
COVER - ENGINE ACCESSORY DRIVE, ROUND, 5.000 BOLT CIRCLE, AMS4490 (UNS M11910)AS3223C (Current)7/16/2018
E-25 General Standards for Aerospace and Propulsion Systems
COVER – ENGINE ACCESSORY DRIVE, SQUARE, 2.653 BOLT CIRCLE, AMS4490 (UNS M11910)AS3221C (Current)7/16/2018
E-25 General Standards for Aerospace and Propulsion Systems
COVER - TYPE XVI, XVII-C, D, E, AND F ENGINE ACCESSORY DRIVEAS3542A (Current)6/20/2018
E-25 General Standards for Aerospace and Propulsion Systems
COVER - ENGINE ACCESSORY DRIVE, ROUND, 8.000 BOLT CIRCLE, AMS4490 (UNS M11910)AS3224C (Current)6/20/2018
E-25 General Standards for Aerospace and Propulsion Systems
Implementing Advanced Technologies in the Sand Casting Supply ChainF-0074-2018-128065/14/2018
ABSTRACT How many castings should be poured before getting a useable part? The ideal answer may be one, but the reality is that the ideal is infrequently realized. What alloy is the part? What is its size? What is the complexity? How is the part complex: many interior cores, many thick to thin section transitions, very thin walls, or something else entirely? No two part geometries will be exactly the same, so the challenges and expectations for each part will be different. At Sikorsky, our sand cast components only seem to be getting more complex, with more demanding dimensional and metallurgical requirements. All of these factors makes the casting of these parts more challenging. This also coincides with a time where lead times and costs to develop a new casting are being scrutinized.
Woodworth, Heather, Jr., William
Cover - Engine Accessory Drive, Round, 10.000 Bolt Circle, AMS4490 (UNS M11910)AS3225D (Current)4/28/2018
E-25 General Standards for Aerospace and Propulsion Systems
Fracture Characteristic Prediction of High-Strength Aluminum Alloy Extrusion using Cockcroft-Latham Ductile Fracture Criteria2018-01-01094/3/2018
Demands are increasing for the reduction of vehicle weight to enhance automobile fuel efficiency and driving performance, with the use of aluminum alloys expected to help. High-strength aluminum alloys (6xxx series, 7xxx series) are called for to enhance crash safety performance, and the prediction of material fracture is a key factor in the application of these alloys. This research presents a FEM model that can predict both tensile fracture and bending fracture when large deformations occur in the extrusion direction of high-strength aluminum alloy extrusion. The fracture characteristics of high-strength aluminum alloy extrusion were obtained by tensile and bending tests, and the factors governing ductile performance were clarified. Fracture was defined in the FEM model using the Cockcroft-Latham ductile fracture model. In addition, the surface crystal grain of aluminum extrusion becomes coarse as a result of the extrusion process, and the hardness distribution also exhibits a soft
Sugimoto, Nao, Takaki, Naoki, Takada, Kenji
Development of Aluminum Suspension Part using by High Pressure Casting of Electro-Magnetic Stirring2018-01-13944/3/2018
The weight reduction of the car suspension parts has a direct influence on the ride and handling. However, the application of nonferrous metal materials, such as aluminum and magnesium, which results in a lighter weight of the suspension can lead to an increase in manufacturing costs compared to cast iron. In this study, vertical type high-pressure die casting using by electro-magnetic stirring (EMS) with A356 alloy in the sleeve was used to control the fine microstructure. Process optimization and part development, as well as unit product and automotive assessment were carried out for electro-magnetic stirring methods. Without making the slurry, the mechanical properties were obtained through optimization of process variables UTS 320MPa, YS 239MPa, EL 13.3%. It also succeeded in mass production with minimum cost increase of aluminum suspension components.
Kim, Minsoo, Kim, Youngchan, Lee, Junmin, Yoon, KwangMin, YounLae, Cho
Advances in Gasoline Direct Injection Fuel Pump Technologies2018-01-03674/3/2018
The introduction of gasoline direct injection (GDI) fuel systems has created numerous technical and manufacturing challenges for fuel system engineers. Direct injection systems run at significantly higher pressures compared to port fuel injection, leading to increased stresses on fuel system components. The demands of GDI pump applications have led to significant innovation opportunities in areas such as high-pressure sealing, control of pumping noise and management of increased loads on pumping elements and pump structure. Shifts in the methodologies for the design of components and materials used, as well as changes to the validation and manufacturing processes, have been required to develop fuel systems for direct injection engines. New technologies for the assembly and joining of materials have also been important to further optimize designs for size, weight, and cost. Recent advances in materials and forming technologies have opened design possibilities to integrate pump sub
Cavanagh, Mark, Pellini, Richard, Pinson, John
An Integrated Approach to Constitutive Modeling and Life Prediction for Automotive Materials2018-01-12134/3/2018
An integrated approach of constitutive modeling and life prediction is presented through introduction of the integrated creep-fatigue theory (ICFT). The ICFT is formulated based on participating deformation and damage mechanisms, which not only describes the cyclic deformation behavior but also the life and fracture mode. Automotive exhaust system materials such as ductile cast iron and austenitic cast steel are used as example materials for demonstration in good agreement with experimental results and metallurgical examinations. This enlightens the understanding of the roles each mechanism plays in low-cycle fatigue (LCF) and thermomechanical (TMF) processes, thus helping material and component design specifically targeting the most damaging mechanism(s) encountered in service.
Wu, Xijia
TOOL, CONNECTOR ASSEMBLY, FOR MIL-C-5015 CONNECTORSAS34801A (Current)1/18/2018
AE-8C2 Terminating Devices and Tooling Committee
Zinc Alloy Ingot and Die Casting CompositionsJ468_201801 (Current)1/9/2018
SIMILAR SPECIFICATIONS—UNS Z33521, former SAE 903, ingot is similar to ASTM B 240-79, Alloy AG40A; and UNS Z33520, former SAE 903, die casting is similar to ASTM B 86-76, Alloy AG40A. UNS Z35530, former SAE 925, ingot is similar to ASTM B 240-79, Alloy AC41A; and UNS Z35531, former SAE 925, die casting is similar to ASTM B 86-82a, Alloy AC41A.
Metals Technical Committee
Zinc Die Casting AlloysJ469_201712 (Current)12/20/2017
Because of the drastic chilling involved in die casting and the fact that the solid solubilities of both aluminum and copper in zinc change with temperature, these alloys are subject to some aging changes, one of which is a dimensional change. Both of the alloys undergo a slight shrinkage after casting, which at room temperature is about two-thirds complete in five weeks. It is possible to accelerate this shrinkage by a stabilizing anneal, after which no further changes occur. The recommended stabilizing anneal is 3 to 6 h at 100 °C (212 °F), or 5 to 10 h at 85 °C (185 °F), or 10 to 20 h at 70 °C (158 °F). The time in each case is measured from the time at which the castings reach the annealing temperature. The parts may be air cooled after annealing. Such a treatment will cause a shrinkage (0.0004 in per in) of about two-thirds of the total, and the remaining shrinkage will occur at room temperature during the subsequent few weeks. Stabilizing results in a decrease in dimensions of
Metals Technical Committee
Identification CastingsAMS2804D (Current)10/12/2017
This specification covers the requirements for identification of castings.
AMS B Finishes Processes and Fluids Committee
Application of Six Sigma Methodology to Improve Product Quality in Injection Molded Parts at Supplier End in Motorcycle Industry2017-01-50119/29/2017
Process Parameters play a vital role in product quality of Injection Molded components. Variation in process parameters will lead to Injection Molded manufacturing defects like Sink Mark, Flow Mark, Silver Streak, Flash, Warping, Weld lines, Jetting, voids, Short Shot & Bubbles. This manuscript is innovative because suppliers (Tier 1 and Tier 2) do not use DoE for standardization of their process parameters in Injection Molding and High Pressure Die Casting. They do trial and error method to arrive at the process parameters which is error prone and time consuming. The variation of process parameters can be optimized using Six Sigma approach, a structured methodology which is Process focused & data driven approach. The purpose of this paper is to present through a case study how the concepts of Design of Experiments, which is a part of Six Sigma Methodology can be used for improving the Injection Molding Process at supplier end reducing defects & hence improving Quality at supplier
Shankaranarayana, Raviprakash
Crack Failure Mode Analysis for Cam-Housing Rocker Arm and Pin2017-01-03583/28/2017
During the extensive testing under NATO and Commercial Standards, crack is observed in camshaft housing to initiate from the eccentric shaft bore and go toward the hold down bolt hole. Hence lab test proposal is originated to induce similar failure in a controlled method and then to compare new design alternatives. CAE analysis follows the same set up as the lab test to duplicate failure mode in stress analysis and fatigue analysis with duty cycle loads, and then figures out two strategies on how to improve the design, including geometry change and material change. In geometry wise, four new design iterations are evaluated for comparison. In material wise, one new material for camshaft housing and five manufacturing effect parameters for pin and rocker arm are compared, including ground, machined, machined and decarburization, casting, as well as casting and nitride. With those comparisons, all manufacturing parameters are compared based on effectiveness to affect the fatigue life
Song, G
A Segregated Thermal Analysis Method for Liquid-Cooled Traction Batteries2017-01-06293/28/2017
Thermal modeling of liquid-cooled vehicle traction battery assemblies using Computational Fluid Dynamics (CFD) usually involves large models to accurately resolve small cooling channel details, and intensive computation to simulate drive-cycle transient solutions. This paper proposes a segregated method to divide the system into three parts: the cells, the cold plate and the interface between them. Each of the three parts can be separated and thermally characterized and then combined to predict the overall system thermal behavior for both steady-state and transient operating conditions. The method largely simplifies battery thermal analysis to overcome the limitations of using large 3D CFD models especially for pack level dynamic drive cycle simulations.
Kuo, John, Garfinkel, George
Fatigue Assessment of Nodular Cast Iron with Material Imperfections2017-01-03443/28/2017
For the design of thick-walled nodular cast iron components, fatigue assessment, especially in the context of local imperfections in the material, is a challenging task. Not only the cyclic material behavior of the sound baseline material, but also the cyclic behavior of materials with imperfections, such as shrinkages, dross and chunky graphite, needs to be considered during the design process of cast iron components. In addition to this, new materials, such as solid solution strengthened alloys, offer new possibilities in lightweight design, but need to be assessed concerning their fatigue strength and elastic-plastic material behavior. If a safe and reproducible fatigue assessment for any component cannot be performed and a secure usage is therefore not given, the cast components are generally rejected, leading to a loss of additional material, energy and money for recasting the component. In this context, four nodular cast iron materials are compared with reference to their cyclic
Bleicher, Christoph, wagener, Rainer, Kaufmann, Heinz, Melz, Tobias
Vote for Tech Briefs 22nd Annual Readers' Choice AwardsTBMG-2607112/1/2016
Each December, we ask our readers to cast their vote for the annual NASA Tech Briefs’ Readers’ Choice Product of the Year Awards. Each month, our editors choose a Product of the Month that has exceptional technical merit and practical value for our design engineering readers.
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