Browse Topic: Materials

Items (80,878)

Steel, Corrosion and Heat-Resistant, Welding Wire, 20Cr - 10Ni - 0.75Cb, High Ferrite Grade

AMS5790G (Current)

5/8/2026

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

AMS F Corrosion Heat Resistant Alloys Committee

Determination of Trace Elements in High Temperature Alloys

ARP1313E (Current)

5/8/2026

This SAE Aerospace Recommended Practice (ARP) describes procedures for the determination of trace elements listed in AMS2280 for Nickel, Cobalt, and Iron-based high temperature alloys.

AMS F Corrosion Heat Resistant Alloys Committee

Requirements Extract for AS5127D Aerospace Standard Test Methods for Aerospace Sealants Methods for Preparing Aerospace Sealant Test Specimens

5/1/2026

This digital standard is a requirements extract of AS5127D Aerospace Standard Test Methods for Aerospace Sealants Methods for Preparing Aerospace Sealant Test Specimens. This file contains a general requirements extraction as well as files that are optimized for use with Doors Classic, Siemens Polarian, and PTC.

software supplement test

SAE-SUP-TEST144/1/2026

<img src="https://wcm14-tst.cld.sae.org/site/binaries/content/gallery/mobilus-brx/digital-supplements/as7140-data-model.png/as7140-data-model.png/sae%3Amedium" alt="AS7140 Data Model">

test software title CURATDEV-467

3/25/2026

467

3/24/2026

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

Digital Supplemental Zip Files Test 3/12/26

SAE-SUP-TEST023/12/2026

SAE SAE SAE SAE SAE SAE SAE2 SAE2 SAE2 SAE2 Link test: https://www.sae.org/standards/as7140-common-open-data-exchange-format-rotorcraft-health-usage-monitoring-systems-codex-hums

3526 aerospace standard

3526-aerospacestandard (Current)3/5/2026

3526 aerospace standard

Aviation Maintenance Committee

3526 information report arinc standard

3526_informationarincstandard (Current)3/5/2026

3526 information report arinc standard

Aviation Maintenance Committee

3526 aerospace information report standard

3526_aerospacestandardinfo (Current)3/5/2026

3526 aerospace information report standard

Aviation Maintenance Committee

3526 specification arinc standard

3526_specification (Current)3/5/2026

3526 specification arinc standard

Airlines Electronic Engineering Committee

3526 characteristic

3526_characteristicstandard (Historical)3/5/2026

3526 characteristic standard

Aviation Maintenance Committee

Durability Validation of Full Vehicle Structures Using Strain Correlation and RLDA-Based Simulations

2026-26-05231/16/2026

Durability validation of full vehicle structures is crucial to ensure long-term performance and structural integrity under real-world loading conditions. Accurate strain correlation between physical testing and finite element (FE) simulations plays a key role in the validation, ensuring reliable predictions of vehicle durability. In this paper, a comprehensive methodology for strain correlation on a full vehicle subjected to torture track testing is implemented. Strategic placement of strain gauges is determined through a combination of static analysis, modal analysis, and identification of critical stress regions in the FE model. Strain gauges were installed on key structural locations of a prototype to capture strain responses under severe loading environments. Simultaneously, vehicle wheel loads were recorded on the torture track to build a detailed Road Load Data Acquisition (RLDA) dataset at critical hard points, Loads measured in terms of wheel loads (WFT) are fed to MBD model to

JAJU, MAYUR, Dokhale, Sandeep, Gadre, Nilesh, Patil, Sanjay

Next-Gen Driver Health and Wellness Platform for Fatigue Detection and Emotional Wellbeing Monitoring

2026-26-06391/16/2026

Driver fatigue and emotional distress are major contributors to traffic accidents, especially among long-haul and professional drivers, making their detection a critical area in road safety and public health. While existing research has explored various sensor-based and wearable solutions to monitor driver states, these approaches often suffer from high cost, intrusiveness, or limited scalability. Camera-based systems have recently gained attention for being less invasive and more practical for real-world deployment; however, many still depend on multiple sensors or cloud-based processing, which raise concerns around energy consumption, privacy, and integration complexity. To address these gaps, we present a sustainable, camera-only Driver Health and Wellness Platform for real-time fatigue detection and emotional wellbeing monitoring. The system leverages a single in-cabin camera and applies lightweight, edge-optimized computer vision models to analyze facial features, eye dynamics

Iqbal, Shoaib, Imteyaz, Shahma

Comprehensive research study examining Tyre wear and its Indian perspective.

2026-26-06041/16/2026

Automobile emissions refer to the gases and particles released into the atmosphere by vehicles during their operation. These emissions contribute to environmental pollution and have an impact on human health and the environment. This paper assimilates findings from a comprehensive research study examining tyre wear and its Indian perspective. Tyre wear understood as a factor affecting road safety, environmental health, and economic sustainability. The study identifies factors affecting tyre wear and provides overview regarding tyre wear generation in India, encompassing road infrastructure, vehicle characteristics, driving patterns, and environmental factors. Moreover, it examines the adverse effects of these particles on human health, such as respiratory ailments and cardiovascular diseases, as well as their impact on ecosystems. This paper delves measures to measure tyre wear and safeguard both environmental and public health. It also covers the tyre wear measurement methodologies to

Joshi, Amol, Khairatkar, Vyankatesh, Belavadi Venkataramaiah, Shamsundara

A Comprehensive Analysis of Sealing Methods for EV Battery Packs: Trends and Insights.

2026-26-01801/16/2026

The widespread adoption of electric vehicles (EVs) has brought about unique engineering challenges, particularly in the design of battery packs, which are central to vehicle performance, safety, and longevity. One critical requirement is maintaining ingress protection (IP) ratings of IP67 or higher to safeguard against water and dust exposure. These ratings are essential to ensure compliance with homologation standards and to meet the demands of diverse terrains and operating conditions. Achieving effective sealing of EV battery packs is thus a key aspect of their design and engineering. This study presents an in-depth analysis of sealing technologies employed in EV battery packs, focusing on four primary types: Adhesive-based sealants, Cure-In-Place Gaskets (CIPG), Foam Cut seals, and Rubber Gaskets. Benchmarking data gathered from more than 90 vehicle models across 20+ brands provide insights into adoption trends, historical shifts, evolution and interface requirements of different

Varambally, Vishakha, Sithick basha, Abubakker, Chalumuru, Madhu, Yaser, K U Syed, Sasikumar, K

Assessing the impact of hole piercing edge quality on fatigue samples for S550MC steel sheet.

2026-26-03061/16/2026

The exceptional strength, formability, and weldability of S550MC steel sheets make them a cornerstone material in the automotive industry. These properties translate into the creation of high-performance automotive components like chassis parts, structural reinforcements, and safety cages, ultimately contributing to enhanced vehicle safety and overall performance. Furthermore, S550MC steel boasts excellent fatigue resistance, a critical factor for ensuring long-term reliability in demanding automotive applications that experience repeated stress cycles. However, beyond its inherent properties, optimizing the performance of S550MC components hinges on a nuanced understanding of the critical relationship between hole edge quality and fatigue failure. This meticulous study delves into the impact of hole-piercing clearance on the quality of the hole edges in modified fatigue samples manufactured from S550MC steel, and its effect on the fatigue life. The surface morphology was assessed

Nahalde, Sujay, Hingalje, Abhijeet, Ughade, Vikas, Singh, Udita, More, Hemant

Experimental and Numerical Investigation of Modal Behaviour in Electric Two-Wheeler Frames

2026-26-03101/16/2026

This research investigates the dynamic characteristics of an electric two-wheeler chassis through a combined experimental and numerical approach. The study commences with the development of a detailed CAD model, which serves as the basis for Finite Element Analysis (FEA) to predict the chassis's natural frequencies and mode shapes. These numerical simulations offer initial insights into the structural vibration behaviour crucial for ensuring vehicle stability and rider comfort. To validate the FEA predictions, experimental modal analysis is performed on a physical prototype of the electric two-wheeler chassis using impact hammer excitation. Multiple response measurements are acquired via accelerometers, and the resulting data is processed to extract experimental modal parameters. The correlation between the simulated and experimental mode shapes is quantitatively assessed using the Modal Assurance Criterion (MAC). This matrix provides a measure of the consistency and similarity between

Das Sharma, Aritrya, Iyer, Siddharth, Prasad, Sathish, Anandh, Sudheep

Investigating Thermal Fatigue Cracks in Exhaust Manifolds of Longitudinally Mounted 1.2L 4-Cylinder Engines

2026-26-04881/16/2026

This study addresses the challenge of ensuring the durability of closed couple exhaust manifolds in the compact engine bays of modern vehicles, focusing on a longitudinally mounted 1.2L 4-cylinder engine. The original sheet metal Exhaust manifold design failed thermal fatigue bench durability test, requiring a complete redesign to improve strength without changing materials. Initial simulation predictions significantly deviated from physical test results, with repeated cracks observed during accelerated thermal fatigue bench testing, despite simulations predicting a higher number of cycles before failure. This difference highlighted the need for a deeper understanding of the manifold's failure modes, primarily thermal fatigue, and mechanical vibration during engine transients. The design of experiment (DOE) approach was used to find the effect of different parameters e.g., gas temperature, surface temperature, air flow, thermal gradient, on the durability result & also to understand

Krishnan, K.S.Gopala, Mishra, Ashutosh, Yadav, Sanjay Kumar, Kumar, Deepak, Tripathi, Manas, kumar, prabhakar

Niobium Alloyed Brake Disc for reduced NVH and emission control

2026-26-02851/16/2026

Recent regulations limiting brake dust emissions have presented many challenges to the brake engineering community. The objective of this paper is to provide a low cost, mass production solution utilizing well known existing technology to meet brake emissions requirements. The proposed process is to alloy the Gray Cast Iron with Niobium. The Niobium addition will reduce wear debris and improve NVH (Noise Vibration Harshness). The test methodology included: Manufacture of disc samples alloyed with Niobium, and Evaluation of airborne wear debris utilizing a pin-on-disc tribometer equipped with emission collection capability. The airborne emission and wear surfaces were further analyzed by Scanning Electron Microscopy, Energy Dispersive techniques (SEM-EDS), X-Ray Diffraction and Optical Microscopy. The cast iron test matrix included four groups; Unalloyed eutectic 4.3% Carbon Equivalent (CE), Unalloyed hypereutectic >4.3% CE, Niobium alloyed Eutectic and Niobium alloyed hypereutectic

Barile, Bernardo, Holly, Mike

Development of Advanced Thermoplastic Elastomeric Mat and Its Study on Thermal Performance of Wireless Charging System

2026-26-02831/16/2026

This study aimed to develop a thermally conductive TPE mat and assess its performance in comparison to an existing antiskid rubber mat, specifically evaluating its impact on wireless charger efficiency. Moreover, morphological and thermal analyses were conducted to establish a correlation between the material behaviours of the new and current thermally conductive antiskid mats. The process of developing the thermally conductive TPE involved utilizing a two-roll mill followed by compression moulding to achieve a 2D sheet shape. Notably, the thermally conductive mat demonstrated a consistent enhancement in charging efficiency over the conventional antiskid mat. To examine the thermal characteristics, thermal characterization techniques including DSC and TGA were employed for both the existing and newly developed mats. FTIR spectroscopy was also utilized to confirm the presence of organic functional groups within the mat. The morphological analysis of the fillers used to enhance thermal

NAIKWADI, AMOL TARACHAND, Mali, Manoj, Patil, Bhushan, Tata, Srikanth

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

2026-26-02881/16/2026

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

Gaware, Amol Chandrakant

Non-metallic inclusions in carburizing steels as a contributory factor for the formation of carbide net

2026-26-02901/16/2026

The article deals with the issue of identifying structural defects that contribute to the formation of a carbide net during thermochemical treatment of steel parts, which negatively affects the mechanical properties complex of finished products. Based on the available data, a theory has been put forward regarding the influence of the present non-metallic inclusions in the carburizing steels structure on carbide formation process in the hardened layer. As an experimentally the samples have been produced from the varying chemical composition alloy structure carburized steel (0.17-0.23 % C, 0.17-0.37 % Si, 0.80-1.10 % Mn, 1.00-1.30 % Cr, 0.03-0.09 % Ti). During microstructure analysis of the samples it has been establish that non-metallic inclusions, in particular sulfides, contribute to the formation of carbides and carbide net in steel due to their high chemical activity with carbon. Thus, contamination of the metal of carburizing steels with non-metallic inclusions is not only a defect

Runova, Iuliia, Chatkina, Mariia, Musienko, Aleksandr

Wetting prediction of power train components under the influence moving components using smooth particle hydrodynamics

2026-26-03841/16/2026

Passenger cars are subjected to extensive conditions ranging from driving through wet roads, water puddles, icy roads, and rain. This can affect the performance of different parts over time, one such aspect is the vehicle corrosion, whose impact is felt on a wide spectrum from aesthetics to safety due to loss of material. The general condition for corrosion mainly requires electrolyte to be present on the metal surface, which is transported through self-soiling and foreign soiling. Vehicle soiling is an important aspect for vehicle design. Amongst the many aspects of vehicle soiling, one important aspect is the prediction of water accumulation that enables prediction of corrosion sensitive regions in the vehicle. Power train components like Engine, transmission and corresponding wiring harness are at highest risk of water-wetting, As the vehicle drives through the water pool the components are not just wet by the direct inflow of water but also by water being splashed by moving

Shukrey, Sarthak, Pattankar, Rohan, Yenugu, Srinivasa

Balancing global and local formability properties through Nb microalloying

2026-26-03031/16/2026

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

Barile, Bernardo

Johnson-Cook model calibration for brittle materials under impact loads

2026-26-03671/16/2026

In the assessment of parts subjected to impact loading, the current process relies on static analysis, which overlooks the significant influence of high strain rate on material hardening and damage. The omission of these effects hinders accurate impact simulations, limiting the analysis to comparative studies of two components and potentially misidentifying critical hot spot locations. To address these limitations, this study emphasizes the importance of incorporating the effects of high strain rate in impact simulations. By utilizing the Johnson-Cook material calibration model, which includes both material hardening and damage models, a more comprehensive understanding of material behavior under dynamic loading conditions can be achieved. The Johnson-Cook material hardening model accounts for the strain rate sensitivity of the material, providing an accurate representation of its behavior under high strain rate conditions. This allows for improved prediction of material response

Pratap, Rajat, Apte Sr, Amol, Babar, Ranjit, Dudhane, Karan, Poosarla, Shirdi Partha Sai, Tikhe, Omkar

Experimental Study on the Role of Hole Expansion Ratio in Enhancing Crashworthiness of Advanced High Strength Steel

2026-26-02951/16/2026

To meet light weighting and safety target, the automotive industry is increasingly using advanced high strength steel (AHSS) materials and advanced manufacturing techniques for complex body parts. To improve energy absorption of automotive body parts, various steel grades are developed by steel manufactures with variety of properties ( YS, UTS, EL %, HER). Also, the formability of AHSS grades (TS > 980 MPa) is challenging due to its limited edge ductility. This study focuses on role of hole expansion ratio in energy absorption of AHSS material. In the study, different AHSS material with variety of microstructure and properties are experimented, with the aim to identify the optimum properties, that can help to enhance crash worthiness of formed part. From experimentation, it is evident that hole expansion ratio plays important role in determining edge ductility, as well as energy absorption. This study may not only help to improve crash performance but also help for light-weighting of

Jain, Vikas, Bandru, Shreenu, Nadarge, Harshad, Misal, Swapnali, Deshmukh, Mansi, Paliwal, Lokesh

Steel-based Laminates for Lithium-ion Pouch Cell of Electric Vehicles

2026-26-01861/16/2026

Aluminium foils have gained traction with EV battery manufacturers for their pouch cell format. Over the years it has evolved as a material of choice, but it is still plagued by issues of stress concentration, swelling due to lower strength and stiffness of base aluminium layer. Preliminary investigation revealed that laminates using steel foil material (thickness <0.1mm) could be a potential candidate for EV pouch cell casing. Thus, steel-based laminate was developed meeting key functional requirements (e.g. barrier performance, insulation resistance, peel strength, electrolyte resistance, formable without cracking at edges, and heat sealing compliant). This innovative patented steel-based laminate was further used to manufacture pouch cell prototypes (maximum capacity 2.5Ah) for key performance tests (e.g. cell cycling, nail penetration and thermal runaway). The study paves the way for a low cost, sustainable and flexible yet strong steel-based laminate packaging material solution

Singh, Pundan Kumar, Raj, Abhishek, Kumar, Ankit, Chatterjee, Sourabh, Verma, Rahul Kumar, Samantaray, Bikash, Gautam, Vikas, Pandey, Ashwani

Comprehensive Durability Assessment of Planet Carrier in Heavy-Duty Tipper Gearboxes Using RLDA Torque Data

2026-26-04431/16/2026

In heavy-duty tippers, where challenging conditions demand high torque, planet carriers play a crucial role by enabling efficient load distribution and torque transmission while supporting gear ratio and speed variation in space-constrained systems such as automatic transmissions, hybrid drivetrains, and electric vehicles. This paper focuses on the comprehensive durability performance assessment of planet carriers using duty cycles derived from RLDA measurements for a heavy-duty tipper gearbox development program. The existing Design Validation Plan (DVP) for the planet carrier considers first gear utilization of 10-15% at 40% vehicle overload, in line with historical data. However, recent trends in mining applications revealed vehicle overloads of 55-65%, leading to an increase in first gear utilization (25-35%). This shift presents challenges for OEMs to enhance design durability while incorporating additional safety margins to meet the demands of a competitive, cost-driven market

Bagane, Shivraj, Pendse, Ameya

Enhanced Methodologies for predicting Automotive Wheel Bearing life and damage using RLDA

2026-26-04821/16/2026

The durability of wheel bearings is assessed in terms of raceway life and flange life. Raceway life focuses on the performance and damage tolerance of rolling elements, while flange life evaluates the structural integrity of wheel flanges under operational stresses. Traditionally, durability predictions relied on conventional design methods and analytic formulas for raceway spalling, as well as static load assumptions for flange fatigue analysis. Recently, integrating design of experiments (DOE) with traditional approaches has enhanced these methods, enabling systematic evaluation of design variables and loading conditions. This paper introduces a methodology for analysing raceway life and damage in automotive wheel bearings using RLDA (Road Load Data Acquisition) data. The process involves acquiring raw deterministic load data, filtering it to preserve high-peaked signals, and transforming the filtered data into block cycles derived from load time histories. Each block cycle contains

Narendra, Vishwanath, Mane, Yogiraj, Paua, Ketan, Singh, Ram Krishnan, Vellandi, Vikraman

Simulation Based Approach to Optimize Electric Vehicle Battery Thermal System

2026-26-03761/16/2026

The performance and longevity of Li-ion batteries in electric vehicles are significantly influenced by the cell temperature. Hence, efficient thermal management techniques are essential for battery packs. Simulation based optimization approaches can enhance these techniques during early product development and life cycle. In this work, a method to optimize the battery thermal system comprising of cooling plate and external insulation is described. The first part is to optimize the cell heat extraction by the cooling plate. The heat transfer coefficient of the coolant is a parameter which can indicate the thermal efficiency of a cooling plate. At the same time, it's important to keep the coolant pressure drop within a reasonable limit. A 1D simulation methodology is described to optimize the cooling channel height based on pressure drop and heat transfer coefficient targets. This methodology is based on empirical correlations and multi-objective pareto optimization. The advantage of

U, Reghunath, P S, Shebin

Thermo-Mechanical Fatigue Assessment of Cylinder Heads Using Advanced Simulation Techniques

2026-26-04651/16/2026

Thermo-mechanical fatigue (TMF) is a critical durability concern for cylinder heads in internal combustion engines, particularly under severe cyclic thermal and mechanical loads. TMF-induced damage often initiates in geometrically constrained regions with high thermal gradients and can significantly reduce component life. As performance demands increase, understanding and mitigating TMF becomes essential to ensure the structural integrity and long-term reliability of engine components. This study presents a simulation methodology for evaluating thermo-mechanical fatigue (TMF), a temperature-dependent low-cycle fatigue (LCF) mechanism that arises from repeated thermal expansion and contraction under mechanical constraints, leading to cyclic plastic deformation and damage. The methodology consists of two key phases. Phase I involves global finite element (FE) simulations—both thermal and structural—to obtain temperature and displacement fields under rated and idle engine conditions

Ghotekar, Sunil, Kumbhar, Dipak Madhukar, Pendse, Ameya

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

Optimizing Busbar Design by Investigating Critical Parameters and Their Influence on Electrical and Thermal Behaviors for Reliable Electric Vehicle Battery Packs.

2026-26-04741/16/2026

With the rise of EVs, researchers are focusing on optimizing busbar design to meet the demands of high energy density, fast charging, and compact battery packs. The busbar design starts with selecting the cross-sectional area based on current-carrying capacity and material type. The width matches or exceeds the battery cell terminal size, while the length is optimized based on space constraints. The research also highlights the risk of busbars to oxidation and corrosion, which increases resistance and decreases thermal conductivity for which Plating and coating techniques are applied to improve surface hardness, durability, and thermal conductivity while minimizing heat loss. Using simulations and experimental validation, the study examines three key design parameters: weld diameter, electrical resistance, and contact resistance. A detailed analysis investigates how weld diameter influences electrical resistance and temperature rise, as well as the impact of contact resistance between

Nogdhe, Yogesh, Singh, Shobit Kumar, Paul, Jibin, Mishra, Mukesh, MENON, Praveen

Material-Optimization in Rib-Stiffened Polymer structures: A Computational & Analytical Study

2026-26-04981/16/2026

Background The demand for lightweight yet rigid polymer components continue to drive innovation in structural design, particularly for applications requiring optimal stiffness-to-weight ratios. This study examines an alternative rib-stiffening approach for polypropylene plates, where conventional single-rib geometries are reconsidered in favor of parallel micro-rib configurations. While single ribs have been extensively studied, the potential benefits of distributed rib architecture remain less explored, particularly regarding their combined bending and shear performance. Key objective: This study systematically evaluates how parallel rib configurations influence mechanical performance in polypropylene plates, with specific focus on:  Bending stiffness preservation through optimized moment of inertia distribution  Shear resistance enhancement via controlled rib spacing  Coupled effect of the bending and shear resistance Prior art and their limitations: Current literature primarily

Sreejith, M P, Jain, Deepak, Maheshwari, Pankaj, Kumar, Mandeep, Ravi, Abhikrishna

Optimizing Stick Slip Performance in Automotive Interiors by Material Selection, Additives, and Design Strategies

2026-26-03251/16/2026

The automotive industry is highly competitive, especially in terms of design and perceived quality. The use of hard plastics with a high gloss finish is driven by styling trends and the push towards zero gaps, making interfaces critical. In-cabin mood lighting is another feature being offered as a theme for interiors. Dashboard or cockpit designs often incorporate a significant amount of polycarbonate-acrylonitrile butadiene styrene (PC-ABS) and polycarbonate (PC). These materials provide strength and design flexibility but have the disadvantage of material incompatibility when used together, leading to stick-slip phenomena. Traditionally, felt tapes were used as interface isolation to solve this problem, but this increased manufacturing costs and assembly complications. The study focuses on the stick-slip phenomenon and material interface modifications. Specifically, it examines selecting the right surface finish on one side of the PC & PC-ABS interface to change adhesion and friction

Mohammed, Riyazuddin, R, Prasath, Rahman, Shafeeq

A method of selectively elevating a Seamless Switch Integrated in Fabric

2026-26-05961/16/2026

This research presents the construction and working principle of Selectively Elevated Seamless Fabric Switch technology aimed at advancing automotive interior design through enhanced aesthetics, functionality, and user experience by providing a tactile surface that is available for operation only during the activated, elevated state. Traditional mechanical switches often suffer from issues such as dust and water ingress, accidental activation, and a fragmented visual profile. The proposed system integrates concealed controls sandwiched with a fabric surface, with switches selectively elevated only upon user interaction. The design incorporates conductive fabric layers and electromagnetic actuation to achieve seamless integration with vehicle interiors while maintaining responsive tactile feedback. The input provided for activating the switch can be a signal such as gesture or proximity of the user’s finger. Upon activation the switch is selectively elevated and ready for operation due

Mohunta, Sanjay, Panchal, Girish, Puthran, Shaunak

Methodology for optimizing the bench testing of Steering I shaft using vehicle level data to reduce overall product development time and cost.

2026-26-05601/16/2026

Steering I-shaft with rubber coupling (or hardy disc) is an important part of complete steering system mainly in body on frame vehicles. Hardy discs are used to dampen the vibrations that transmit to steering wheel through frame, steering gear and I-shaft. They also support to accommodate the variation between frame and BIW of body on frame vehicles. They are made up of rubber or other polymer composites, which have less torsional stiffness as compared to metals. The overall torsional stiffness of steering system reduces since the hardy disc is used in series in steering system, that impacts on the overall performance of steering system. So, during development I shafts with different design, stiffness of hardy discs are used to optimize the steering and NVH performance of vehicle. Considering the development time and cost, each design of I-shaft cannot be validated at vehicle level. The torsional and axial force or displacement of hardy disc is measured at vehicle level on different

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

2026-26-01551/16/2026

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

Venkatesh, Murali, Raghu, Arun, Bhramanna, Amol

Wheel side load calculation using the strain measurement on swingarm and duty cycle development

2026-26-05831/16/2026

Typically duty cycle development for any component carried out in the absence of direct acting load will be based on the measured strain from the Road Load data Acquisition(RLDA) and comparing it with the rig level testing. The biggest drawback from such an approach is the fact that the selected loads can be drastically different from the actual experienced peak load from the actual RLDA. This happens because the strain gauges will have sensitivity toward all three directional loads and sometimes due to complex structure design uni-directional sensitive locations are difficult to find out or strain gauge. This will lead to over predicting the loads in some cases and the selected load may end up yielding the component in a single cycle itself. This paper discusses the method employed to calculate the loads at the input load location using the strain gauges which are cross sensitive and using that input loads to select the loads for the testing of the component. Also it talks about the

Anandh, Sudheep, Prasad, Sathish, R S, Mahenthran

Determination of Acrylonitrile Content in Nitrile Butadiene Rubber Vulcanizates by Py-GCMS Techniques

2026-26-05461/16/2026

Nitrile Butadiene Rubber (NBR), a copolymer of butadiene and acrylonitrile is known for its superior resistance to hydrocarbon oil, low gas permeability and excellent thermal stability. It is extensively used in seals, O-rings, conveyor belts and pneumatic tires. It is worth mentioning that these performance attributes are predominantly influenced by acrylonitrile content. While solid-state 13C Nuclear Magnetic Resonance (NMR) is an established technique for structural characterization of rubber vulcanizates, its high cost and accessibility limits its application in routine industrial analysis. This study aims to develop Pyrolysis-Gas Chromatography/Mass Spectrometry (Py-GCMS) as a robust, precise, cost-effective alternative to determine acrylonitrile content in NBR vulcanizates. This research demonstrates and establish a method to determine the acrylonitrile (ACN) content in finished rubber vulcanizates through pyrolysis gas chromatography-mass spectrometry (Py-GCMS). This method

Samanta, Rajyasree, Ghosh, Debojit, Anjana, Kanhaiya, Sen, Amit, Guria, Biswanath, Chanda, Jagannath, Samui, Barun, Ghosh PhD, Prasenjit, Mukhopadhyay, Rabindra

Life Cycle Assessment of Automotive Cables and GHG Emission Reduction Scenario in Indian Context

2026-26-02401/16/2026

Globally, the emissions share of transport is 15%, out of which more than 2/3rd emissions are contributed by road transport as per 2014 report of Intergovernmental Panel on Climate Change (IPCC). The need of mitigation measures in transport sector has been realised however the study of life cycle emission needs to be done with the tailpipe emissions so that some holistic solution can be worked upon. Strikingly, in the life cycle studies of a passenger car, it was found that the share of raw materials related to copper is around 50% of the total amount of raw material used and the share of copper in the curb weight of vehicle is just 1%. Also, for an Internal Combustion Engine vehicle (ICE), mostly the copper is used in the wiring harness. In this paper, the life cycle assessment of wiring harness is done to understand the environmental impacts throughout the life cycle stages. The comparative study of aluminium alloy and copper has also been done to know the change in environmental

Kumar, Naman, Bawase, Moqtik, Thipse, Sukrut

Review on the flyback converter design for multi-output

2026-26-02001/16/2026

With the increasing demand for DC loads, DC-DC converters have become indispensable in modern power electronic architectures. With high-voltage applications typical DC-DC converter topologies are required which include isolation for safety and voltage level conversion. Among various isolated converter topologies, the flyback converter is widely favored for low-power applications, typically under 100 W, due to its simplicity and cost-effectiveness. Like other DC-DC topologies, the flyback converter can operate in either continuous conduction mode or discontinuous conduction mode (DCM). The work have focused on the design and performance analysis of a flyback converter operating in DCM, with a specific emphasis on magnetic component design and loss evaluation. A 55 W multi-winding flyback converter employing a passive snubber circuit is studied and implemented. The loss analysis is done with switch losses around 3.4W and the coupled inductor core losses around 1.5W and copper losses

S, Denis, Deshpande, Prathamesh Pravin, Deshpande, Rohan

Clutch Thermal Adequacy Assessment in Repeat Restart Launch Condition on Gradient

2026-26-04341/16/2026

The clutch is a mechanical device that engages and disengages power transmission from the engine to the wheels. It consists of the clutch disc assembly and cover assembly. The clutch disc, with friction material linings, is mounted on the transmission shaft and gets clamped between the flywheel and cover assembly to transmit power as required. However, wear and tear occur due to the differential speeds and slippage between the engine and transmission during operation. Clutch performance is assessed for its thermal behavior under repeat restart conditions on steep gradients, which is essential for the reliability and durability of commercial vehicle clutches. Repeat restart test is a key test to assess clutch performance on a 12% gradient. This test replicates real world scenarios, such as truck launches on hilly terrains under full load, where the clutch experiences significant slippage due to speed differences. This generates heat, and repeated engagements can cause the temperature to

Munisamy, Sathishkumar, Chollangi, Damodar, Mane, Sudhir

Failure Prevention of Permanent Deformation in HNBR Elastomeric Diaphragms Used in CNG Valve Applications

2026-26-02941/16/2026

Hydrogenated nitrile butadiene rubbers (HNBR) and its derivatives have gained the significant importance in automotive compressed natural gas (CNG) valve applications. In one of the four-wheeler CNG valve application, HNBR elastomeric diaphragms are being used for their excellent sealing and pressure regulation properties. The HNBR elastomeric diaphragm was developed to sustain CNG pressure more than 10 bars. However, it was found permanently deformed under 4 bar pressures. In the present work, a set of experiments were carried out in order to find out the primary root cause of diaphragm permanent deformation and preventing the failure for safe usage of the CNG gas. HNBR diaphragm deformation investigation was carried out using advanced qualitative and quantitative analysis method such as Soxhlet Extraction Column, Fourier Transform Infrared Spectroscopy (FTIR), Differential Scanning Calorimetry (DSC), Optical Microscopy (OM), Scanning Electron Microscopy (SEM) and Thermogravimetric

Patil, Bhushan Gulab, NAIKWADI, AMOL, Mali, Manoj, Tata, Srikanth

Fatigue Life Prediction Methodology for Vehicle Suspension System and correlation with Physical Test

2026-26-04591/16/2026

Fatigue Analysis is a safety critical area in design engineering for load bearing members. The design of a durable suspension system forms the foundation of vehicle architecture. The challenge lies in accurately predicting fatigue in critical areas to reduce field failures, primarily due to the absence of a validated methodology for fatigue calculation. This study provides an overview of fatigue assessment for Knuckle assembly/Rear Twist Beam based on digital Road Load/test Data for Finite Element Analysis (FEA) process for design development. This study makes use of Computer Aided Engineering (CAE) solvers such as Optistruct for model setup and fatigue tool such as nCode/FEMFAT for Fatigue Analysis. The methodology used for Fatigue estimation of rear suspension components such as Rear Twist Beam and Knuckle assembly is based on Digital Road Load Data/duty cycle loads applied to the suspension components at the hard point location at assembly level. The fatigue process used for

Kokare, Sanjay, Nagapurkar, Tejas, Iqbal, Shoaib

Novel Approach on Material characterization Testing of various Wiring Harness

2026-26-05481/16/2026

The automotive wiring harness (length of 4-5 km) is a very important and complex system in the development of a modern car due to a lot of new electric & electronic components and sensors. It is a very sensitive material unlike metals and is considered as a composite which is highly anisotropic in nature, as it consists of several different layers of copper/aluminum strands and insulation. Because of insulation, wiring harness exhibits viscous plastic behavior which is crucial in determining the durability and long-term performance of the cables. Material properties play an important role in determining the behavior of wiring harness after assembly into the car. Wiring harness may undergo Bending, Torsion and Tension loads, causing the stress and strain in the individual electrical wires. The lack of CAE validation of the wiring harness routing may lead to extra costs for the automotive OEMs over a period. This paper describes the novel method of Testing the Cables and Bundles used in

Beesetti, Siva, Kalkala Balakrishna, Prasad, James Aricatt, John, SHAH, Dipam, Tas, Onur, Krogmann, Stephan

Preventing thermal run-away using shape memory alloy

2026-26-00091/16/2026

Title: Preventing thermal run-away using shape memory alloy Rini Reginald, Ashish Chauhan, Saswat Rout, Venkatesh Muthukrishnan Mercedes-Benz Research and Development, India Key words: Thermal Runaway, Active and Passive Safety, Shape Memory Alloy, Nitinol, Literature Survey, Structural Simulation Abstract The present disclosure pertains to advancements in battery modules for electric vehicles (EVs). Addressing the critical issue of thermal runaway in high-voltage battery packs, this invention introduces a novel battery module designed to enhance safety of the vehicle. The battery module comprises a plurality of battery cells housed within an enclosure, electrically connected to the vehicle's circuit via busbars and innovative connectors made of Shape Memory Alloy (SMA). These connectors are engineered to transition between two states: a first state where they facilitate electrical coupling and a second state where they isolate the battery cells upon detecting temperatures exceeding a

Reginald, Rini, Rout, Saswat, VENKATESH, Muthukrishnan, Chauhan, Ashish Jitendra, Selvaraj, Elayanila

Reliability of Rubber Grommets by Stochastic Analysis of Geometric Tolerances

2026-26-05011/16/2026

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

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

Optimized Panel Design for Reducing Seal Squeak and Chucking in Door & Body Seals

2026-26-03411/16/2026

Quieter cabins in an automobile are the new era, they provide customers with pleasurable driving experience. Squeak and Rattle are spoil sport for any OEM that aim to improvise customer driving experience. Their nonlinear nature makes it difficult to formulate design frontloading methods. The issue of seals rubbing against the body & door interface is a clear sign of seal squeak & seal chucking. Seals are applied with anti-friction coatings to avoid stick slip phenomena between EPDM and painted panel. Primary root cause for seal squeak is coating erosion. The challenge lies in determining whether the body or the closure side contributes to the seal issue. This paper presents a distinctive approach for identifying the seal squeaking noise and enriches on the new modelling methods for seal interaction with door and body interfaces using FE software. The proposed method was able to highlight the locations along the door-body interface for squeak noise. The approach for reducing the

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

Items per page:

1 – 50 of 80878