Browse Topic: Composite materials

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DESIGN & STATIC STRUCTURAL ANALYSIS OF COMPOSITE PROPELLER SHAFT: A COMPARATIVE STUDY2026-26-0297To be published on 01/16/2026
Advanced Fiber Reinforced Polymer (FRP) composites have emerged as an important class of engineering materials for load bearing applications with all round properties for many engineering and social applications. Composite materials are created by combining two or more dissimilar materials with a viewpoint to improve the properties or to create materials with desired properties. Substituting composite structures for conventional metallic structures has many advantages because of higher specific strength and stiffness of composite materials. The role of composite material in weight reduction and fuel saving in automobiles is highly significant. Advanced composite seems ideally suited for long, power drive shaft applications. Their elastic properties can be tailored to increase the torque and the rotational speed at which they operate. Composite driveshaft is designed based on filament winding technology for higher strength and torque applications. In the present work, a comparative
Indla, Veneil Sai, REDDY, NEERATI, Kopparapu, Laxmi kanth
Lightweight Cascade Design Using Type IV Cylinders for Efficient Hydrogen Gas Logistics in India2026-26-0485To be published on 01/16/2026
Hydrogen mobility in India faces a key challenge in the form of high transportation and logistics costs, particularly in tier-II and tier-III cities where dedicated pipelines are not yet feasible. Current methods using traditional steel based cascades are heavy, inefficient, and limit payload capacity. This paper presents a novel lightweight cascade system designed to enhance the efficiency of hydrogen gas logistics using Type IV composite cylinders and an aluminium structural frame. The design adheres to PESO (Petroleum and Explosives Safety Organisation) standards and achieves a structural weight reduction of 52%, owing to the use of carbon fibre composite cylinders and aluminium framework. Field level analysis demonstrates that the gas transport efficiency is improved by a factor of 2.5 compared to conventional steel based systems when used in heavy duty trucks. This innovation offers a significant step forward in enabling economically viable hydrogen distribution for mobility
Parasumanna, Ajeet Babu, Muthusamy, Hariprasad, Ammu, VNSU Viswanath, Kola, Immanuel Raju
Composite Secondary and Tertiary Structure for Landing Gear AIR6827 (Current)11/26/2025
This document will contain guidance and considerations for the use of composite materials on non-primary structure for landing gear systems. Content to include design considerations, conditions and applications where composites are feasible/beneficial, high-level descriptions of various manufacturing processes, and certification/validation considerations.
A-5B Gears, Struts and Couplings CommitteeNEW
Development and Qualification of Composite Landing GearsAIR5552A (Current)11/26/2025
This information report provides general guidance for the design considerations, qualification in endurance, strength and fatigue of landing gear using composite components as principle structural elements. The information discussed herein includes the development and evaluation of design data considering: the potential for imbedded manufacturing defects, manufacturing process variations, the component operating environment, potential damage threats in service, rework and overhaul, and inspection processes. This AIR mainly discusses the use of thick composites for landing gear structural components. Considerations and recommendations provided in this AIR may therefore differ greatly from considerations and recommendations found in widely accepted composite design references such as CMH-17 and Advisory Circulars such as AC 20-107(B).
A-5B Gears, Struts and Couplings CommitteeNEW
Cast Aluminum Alloy Composite 4.6Cu - 3.4Ti - 1.4B - 0.75Ag - 0.27Mg (205.0/TiB2/3p-T7P) Sand Cast, Solution, and Precipitation Heat TreatedAMS4482B (Current)11/25/2025
This specification covers a dilute aluminum/TiB2 metal matrix composite in the form of sand castings.
AMS D Nonferrous Alloys Committee
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 TreatedAMS4471C (Current)11/25/2025
This specification covers a dilute aluminum/TiB2 metal matrix composite in the form of investment castings.
AMS D Nonferrous Alloys Committee
RESEARCH OF THE EFFECTS OF INTEGRATION INTO ARMOR ON THE PERFORMANCE OF SPINTRONIC MICROWAVE DETECTORS2024-01-333411/15/2024
ABSTRACT The authors studied the effects of different types of armor on the performance of spin-torque microwave detectors (STMD). Working prototypes of novel nano-sized spintronic sensors of microwave radiation for battlefield anti-radar and wireless communications applications are being integrated into Sensor Enhanced Armor (SEA) and Multifunctional Armor (MFA) and tested in SEA-NDE Lab at TARDEC. The preliminary theoretical estimations have shown that STMD based on the spin-torque effect in magnetic tunnel junctions (MTJ), when placed in the external electromagnetic field of a microwave frequency, can work as diode detectors with the maximum theoretical sensitivity of 1000 V/W. These STNO detectors could be scaled to sub-micron size, are frequency-selective and tunable, and are tolerant to ionizing radiation. We studied the performance of a STMD in two different dynamical regimes of detector operation: in well-known traditional in-plane regime of STMD operation and in recently
Bankowski, Elena, Meitzler, Thomas, Pesys, Tomas
Regression Test 08/22/24 - Tatsiana twrtwtwSAE-PP-0944808/22/2024
QA Test
Mutagaana, Festo
Effect of environmental factors on the function of an Automotive Luggage Cover of a passenger vehicle – A case study2024-26-022801/16/2024
Abstract: - Automobile OEMs, universally, have always given high priority to the Luggage Area of the vehicle. Luggage Area primarily includes a Load Floor (the load bearing part), Side & Rear garnishes & the Luggage Shelf (or the Parcel Tray) for covering the luggage. The Parcel Tray makes the Luggage Area look neat and aesthetically appealing & is occasionally also used for carrying small items like files, papers, cushion, tissue box etc. The article under consideration in this paper is a Luggage Cover made from thermoplastic composite such as PP-Compounds (with Glass-fiber or Wood-powder), with rotating hinges towards the cabin side. Such types of Covers are predominantly in use in many markets including India. In the vehicle, the Luggage shelf is suspended on the Side Trims or Garnishes & has an elastomer interface with the back Door. The back door tends to be opened and closed in frequent intervals and the elastomer tends to harden with time. This leads to increased load on
Sreejith, M P, Khandelwal, Lokesh, Sandilya, Arnab, Natu, Mandar R, Ray, Amulya Kali, Handa, Rajat
Airless tyres in the LEON-T project: How can they be modelled?2024-26-037501/16/2024
For more than a century, pneumatic (air-inflated) tyres have totally dominated the market for road vehicle tyres. However, in the recent two decades, interest has grown in developing airless tyres. Some of the authors were involved in design of an early version in composite material 15-30 years ago for passenger cars. Presently, the EU project LEON-T includes a part in which prototypes for innovative heavy goods vehicle (HGV) tyres are developed, with the main purpose to reduce noise emission by 6 dB. To reduce noise that much it is believed that airless tyres are needed. A special challenge is to get a durable design able to carry typical truck tyre loads. This paper introduces the principal design of airless tyres. Airless tyre prototypes are intended to be developed by partner Euroturbine, in cooperation with mainly Applus+ IDIADA, VTI and subcontractor Lightness by Design. The tyre consists of a rim, load-carrying spokes, composite belt and rubber tread. The primary focus is on the
Anantharamaiah, Bharath, Fragerberg, Linus, Sandberg, Ulf, Hansson, Hans-Erik, Garcia, Juan J.
Effect of Ceramifiable Silicone Rubber Composite based Thermal Insulators in Battery Packs2024-26-035101/16/2024
Silicone and rubber composite, often called Ceramifiable Silicone Rubber (CSR) has proven to show excellent mechanical and thermal properties. CSR materials have been mainly used in industrial applications like electrical insulating cables, decorations, and fire-proof materials. The mechanical and ceramifiable properties of CSR can be altered by changing the silicone rubber matrix and by adding the right additives or fillers. In this work, we prove the potential of CSR composites as thermal insulating materials in battery packs. Specifically, we explore the usage of CSR inside the battery pack to improve safety during thermal events. We also characterize the material properties before and after exposing the CSR composite to elevated temperatures and flame. Finally, we investigate the effectiveness of the CSR composite sheet in preventing or delaying cell-to-cell thermal propagation during a thermal runaway event inside the battery pack. Our experiments show that the CSR composite sheet
Nambisan T M, Praveen Kumar, H, Manjunatha, R, Pavan, P, Hari Prasad Reddy, G M, Bharath, Kulkarni, Mukund Aravind, Sundaram, Saravanan
HEADLINER COMPOSITION OPTIMIZATION WITHOUT COMPROMISING THE SAFETY AND PERFORMANCE2024-26-019001/16/2024
Reducing material wherever there is a possibility in automobile industry is inevitable for weight and cost saving. This paper explains about the possibilities of optimizing the material composition of automotive Headliners (also called as Roof liners) without affecting the performance and safety criteria. In this paper, we are targeting at optimizing the individual constituents of a composite Headliner. A conventional Headliner comprises of many sandwich layers of which PU foam shares the major percentage of the composition contributing to 80% of the Headliner thickness. In this paper, we are discussing about the optimization done in Headliner sandwich constituents without affecting the core performance parameters of Headliner such as curtain airbag deployment, ergonomic regulations, drop test etc. By incorporating this change, without significant changes in other layers, overall weight reduction of ~5% and overall thickness reduction of ~15% is achieved. Key words: PU- Polyurethane
D, GOWTHAM, VADLA, VILAS, BHASKARARAO, PATHIVADA, sai, Konduru, bornare, harshad, RITESH, KAKADE, Deoli, Manish, Kakani, Phani Kumar
An Aerodynamic Equation of State—Part I: Introduction and Aerospace Applications - QA Test Tatsiana01-17-01-000104/19/2023
Abstract In subsonic aircraft design, the aerodynamic performance of aircraft is compared meaningfully at a system level by evaluating their range and endurance, but cannot do so at an aerodynamic level when using lift and drag coefficients, CL and CD , as these often result in misleading results for different wing reference areas. This Part I of the article (i) illustrates these shortcomings, (ii) introduces a dimensionless number quantifying the induced drag of aircraft, and (iii) proposes an aerodynamic equation of state for lift, drag, and induced drag and applies it to evaluate the aerodynamics of the canard aircraft, the dual rotors of the hovering Ingenuity Mars helicopter, and the composite lifting system (wing plus cylinders in Magnus effect) of a YOV-10 Bronco. Part II of this article applies this aerodynamic equation of state to the flapping flight of hovering and forward-flying insects. Part III applies the aerodynamic equation of state to some well-trodden cases in fluid
Burgers, Phillip
An Aerodynamic Equation of State—Part I: Introduction and Aerospace Applications - QA Test Tatsiana01-17-01-0001-TEST-REC04/19/2023
Abstract In subsonic aircraft design, the aerodynamic performance of aircraft is compared meaningfully at a system level by evaluating their range and endurance, but cannot do so at an aerodynamic level when using lift and drag coefficients, CL and CD , as these often result in misleading results for different wing reference areas. This Part I of the article (i) illustrates these shortcomings, (ii) introduces a dimensionless number quantifying the induced drag of aircraft, and (iii) proposes an aerodynamic equation of state for lift, drag, and induced drag and applies it to evaluate the aerodynamics of the canard aircraft, the dual rotors of the hovering Ingenuity Mars helicopter, and the composite lifting system (wing plus cylinders in Magnus effect) of a YOV-10 Bronco. Part II of this article applies this aerodynamic equation of state to the flapping flight of hovering and forward-flying insects. Part III applies the aerodynamic equation of state to some well-trodden cases in fluid
Burgers, Phillip
An Aerodynamic Equation of State—Part I: Introduction and Aerospace Applications01-17-01-000104/19/2023
In subsonic aircraft design, the aerodynamic performance of aircraft is compared meaningfullyby evaluating their range and endurance, but cannot do so atwhen using lift and drag coefficients,and, as these often result in misleading results for different wing reference areas. This Part I of the article (i) illustrates these shortcomings, (ii) introduces a dimensionless number quantifying the induced drag of aircraft, and (iii) proposes anfor lift, drag, and induced drag and applies it to evaluate the aerodynamics of the canard aircraft, the dual rotors of the hoveringMars helicopter, and the composite lifting system (wing plus cylinders in Magnus effect) of a YOV-10. Part II of this article applies this aerodynamic equation of state to the flapping flight of hovering and forward-flying insects. Part III applies the aerodynamic equation of state to some well-trodden cases in fluid mechanics found in fluid-mechanics textbooks.
Burgers, Phillip
Optimization of Buckling Load of Thin Hybrid Composite plate of Carbon/Glass Epoxy using Taguchi Approach2022-28-050211/18/2022
The aim of the paper is to analyze the effect of the design factors on the buckling load of the thin hybrid laminated composite plate made of Carbon/Glass Epoxy fiber. The detailed investigation is done on the stacking sequence, stacking angle, cut-out orientation whose shape is elliptical and thickness of the plate. For optimization the Taguchi approach of Design for Experiments (DOE) is being considered. For obtaining the combinations L16 orthogonal array is implemented using MINITAB and analysis is carried using ANSYS software. Analysis of each factor is done and significance of each factor is decided based on the 0.05 confidence level. Normal Probability and Residual versus Fitted Values plot is being obtained. Based on the delta values rank for each factor which have four levels are given. The boundary condition of simply supported on all edges is considered during the simulation for calculating the critical buckling load.
Gore, Renuka, Bhaskara Rao, Lokavarapu
Optical Black Coatings On Carbon Fiber Reinforced Composite Sandwich Structure With Aluminum Honeycomb Core For Satellites Applications.2022-26-114105/26/2022
The composite sandwich structure has been in use in space applications as a result of its high strength to weight ratio coupled with excellent compressibility strength. In particular, there has been tremendous demand for honeycomb sandwich structures for satellite application in recent years. Currently, a major problem needs to be addressed concerning reflections from satellite structures which leads to capturing in-accurate data of celestial bodies by ground-based astronomy. In the light of the above, this paper focuses on the development of novel optical black coatings on Carbon fiber reinforced composite sandwich structures with aluminum honeycomb core. A thin layer of Multi-Walled Carbon Nanotubes black coatings was developed on the surfaces of Carbon fiber reinforced composite laminate of the sandwich structure using Chemical Vapour Deposition technique, to provide low scattering and low reflective surface. Three-point bending test are performed for evaluating the Youngs modulus
CS PhD, Ramesh, J, Sudharshan, Chaurasia, P Harsh
Tuning of blade natural frequencies outside high excitation region by using Ceramic Particle Reinforced Composite Materials for a typical Gas Turbine Engine Compressor Blade 2022-26-114405/26/2022
Composite materials have time and again proven to be highly useful, especially in the aerospace industry with the increasing need for light-weight materials albeit with high stiffness to strength ratios. The Ceramic Particle Reinforced Composites can be effectively utilized in tuning the natural frequencies of components by varying the volume fractions up to 60% with the help of Representative Unit Cell (RUC) Models. The aim of this paper is to tune the natural frequencies of a typical compressor blade used in a gas turbine engine by modifying the material properties without changing the design profile significantly. The design profiles of blades are arrived at after a lot of engineering iterations from aerodynamics stability point of view and are also finalized based on meeting key performance parameters. However, the structural analysis studies are carried out after the profile generation, which may sometime predict that the natural frequencies are within the high excitation range of
Putrevu, Ravi, Kari, Sreedhar
Bird strike analysis on nanocomposite materials for aerospace applications2022-26-114505/26/2022
Over the years, bird strike has become a serious threat as it is inevitable and can be catastrophic. Several accidents occur due to the bird collision with wing leading edges, causing serious structural damage that may be permanent. Therefore, the failure induced by birds on the leading edge has persuaded much research interest. To heighten the impact resistance during bird strike with the leading edge of the wing, nanocomposite materials are proposed as it has improved characteristics like high surface-to-volume ratio, enhanced mechanical properties like high ductility, fracture toughness with no decrease of strength in structure. In order to achieve material constants of the nanocomposites, the finite-element method (FEM) and representative volume element (RVE) which is a micromechanical analysis approach will be considered. A comparative study will be done on different volume fractions of nanofillers impregnated with the composite material to find the optimum material properties
Neigapula, Keerthana, Anand, Sumit, Devi, Monisha, Tiwari, Anawil, Kumar, Siddharth
A comparative study between Flax-Fiber Reinforced Polymer and Balsa wood for Aero-structure applications. 2022-26-119905/26/2022
When air flows over a wing, a pressure difference is generated between the upper and lower camber of the wing. This pressure difference is responsible for lift generation. Since the wing is the primary lifting surface of all aircraft, the structure itself must be capable of handling all the loads imposed upon it. This study aims to perform a trade-off between Balsa wood and a natural fiber composite namely Flax Fiber Reinforced Polymer and evaluating their performance using ANSYS. Balsa wood is the most common material used for building homebuilt remote-controlled aircraft. This makes the aircraft light but restricts its performance as it cannot handle cyclic loads over a period of the cycle. Thus, a natural fiber composite is being chosen as a substitute for the conventional Balsa wood. The wing is modeled using SOLIDWORKS 2018 and includes 5 ribs and a rectangular spar at the maximum thickness/chord %. The composite material is built using ANSYS ACP wherein all the laminates and
Phatarphod, Soham, Swain, Prasant Kumar, Sharma, Narayan, Maiti PhD, Dipak Kumar
New Material for Battery Enclosures of Electric Vehicles2022-01-026703/29/2022
In recent years, aluminum alloys have become the dominant material for battery enclosures used in battery electric vehicles (“BEV”) due to their low density. Aluminum battery enclosures, or other platform parts, typically provide weight savings of ~40% compared to equivalent commercially-used steels. The best-suited materials for battery enclosures are 6000-series and 7000-series aluminum alloys. Despite its light weight and recyclability benefits, the aluminum alloys have a crucial disadvantage if the heat generated by the battery cells raises the temperature of battery enclosures above 600°F/315°C. At the exposure of more than 300 sec at 600°F/315°C or higher, the yield strength, especially for parts that are in direct contact with the battery cells drastically drops by more than 70%, and in the critical situation of fire (~2200°F/1205°C), the batteries enclosures fail within ~5 sec, creating a paramount safety concern for BEV passengers. New high strength steel for cold stamping
Vartanov, Gregory
Selection of suitable lightweight materials for various Automotive Vehicles and their components through Advanced Computational Investigations 2022-01-040703/29/2022
Generally, most of the fractions are occurred because of a lack of resistivity knowledge in internal structure level at abnormal loading conditions such as shock load, impact load, aerodynamic load, etc. Aforesaid loads drastically affect the structural performance of a component. The detailed pre-defined study about aforesaid loading environments and their side effects can provide the details of withstanding capability at peak loading conditions. This work examined the behavior of composite materials, which are subjected to sudden loading conditions at different real-time applications. Automotive vehicles and their components such as four-wheeler bumper, main bike stand, and automotive passenger bus are predominantly imposed these comprehensive investigations. The three primary different composites such as CFRP [Carbon Fiber Reinforced Polymer], GFRP [Glass Fiber Reinforced Polymer], and KFRP [Kevlar Fiber Reinforced Polymer] are selected and implemented under crash analysis with the
R, Vijayanandh, Gnanasekaran, Raj Kumar, Kulandaiyappan, Naveen Kumar, Raji, Arul Prakash, Madasamy, Senthil Kumar, Kesavan, Kandasamy, Subramaniam, Indira Prasanth
Investigation of Al2O3-Ni coated cast iron brake rotors under modified brake dynamometer test standards2022-01-030903/29/2022
Due to the reduced or less-frequent usages of the friction brakes and the lower brake rotor temperature on electrical vehicles (EV), corrosion would much likely occur on brake rotors. Using hard braking to clean the corroded rotor surfaces often leads to extra rotor surface wear. Improvement in corrosion and wear resistance is an important technological topic to brake rotors for EVs. Many original equipment manufacturers (OEM) and their suppliers are exploring surface treatments including laser cladding and thermal spray processes on cast iron rotors to combat the corrosion issues. However, mentioned surface coating processes increase the cost of brake rotors and there is a need to search for cost-effective coating processes. In this research, a new Al2O3-Ni composite coating was proposed for preparation of a commercial cast iron brake rotor using both plasma electrolytic aluminating (PEA) and electroless nickel plating (ENP) processes. The added nickel was to fit in the intrinsic
Cai, Ran, Sun, Jiayi, Zhang, Jingzeng, Tjong, Jimi, Foots, Sean, Lavelle, Mark, Nie, Xueyuan
Polypropylene composite material for light weight fuel tank protection shield2022-01-039603/29/2022
The fuel tank shield provides a protective boundary between the fuel tank and vehicle driveline in the event of a high-speed crash. Hence, it is important from the safety standpoint. The part must be carefully engineered to meet the challenging requirements in terms of stiffness, deflection, toughness, dimensional stability and thermal stability. In this paper, long glass fibre filled polypropylene material compound was selected and developed to meet the mentioned requirements for this part with significant mass reduction over other materials. The combination of material, optimized part and tool design led to weight savings and considerable cost reduction. This is a ready to mold material used in injection molding process.
Govindaraj, Karthik, Jayashankar, V, C, Karthiban
Wear and Friction of PTFE and PEEK Coated Cast Iron Piston Ring 2022-01-038003/29/2022
In engine 30% of the total energy is lost due to the friction between piston ring and cylinder liner due to their constant rubbing motion. A piston that reciprocates at high speeds has piston rings that constantly scrape against the wall leading to high frictional losses within the engine. The engine has to work against this resistance to provide the required power, and hence it will consume more fuel. For this reason, material used for these components is more crucial. Reduction of surface friction between moving parts in order to increase overall efficiency can be achieved by suitable coating. The most commonly used piston rings are coated with chromium layers that are electroplated which is being replaced by chrome plating. Low coefficient of friction (COF) and high wear resistance can be achieved by self-lubricating coating of PTFE and PEEK polymer-based composite coatings. Experimental results showed that the PEEK and PTFE coating performed better in terms of friction and wear
Rajendran, R.
Development of In Mold Coating Clear Coat Paint for Carbon Fiber Sheet Molding Compound Roof.2022-01-041203/29/2022
Carbon Fiber Reinforced Plastics (CFRP) is superior in the specific tensile strength and the specific rigidity which used for various products in aerospace and sports industry. With increasing attention to Carbon Neutral (CN) in the world, the vehicle electrification and the lightweight are expanding. As a result, the application of CFRP to luxury cars, electric cars and sports cars, is increasing. It is also applied by Lexus LC, RC-F and Toyota 86 GRMN. However, there are two technical concerns. First is the durability which caused by CFRP resin characteristic. Second is poor appearance which is caused by CFRP surface pinholes. In order to secure the good durability and surface appearance, CFRP must be required pre-treatment before painting (putty applying a filler for the plastics surface coverage and surface sanding) and the multiple painting. Current painted CFRP is not suitable for the mass production due to long and complicated process. As a result, the applied vehicle is limited
Ito, Katsunori
Research on electromagnetic shielding technology of military vehicle-mounted shelter based on material-structure co-design2022-01-042603/29/2022
In order to meet the needs of modern warfare, the research on electromagnetic shielding technology of military vehicle-mounted shelters and improving the electromagnetic shielding performance of shelters will play an increasingly important role in the protection of advanced electronic equipment. At the same time, it is also the core of the development of military vehicle-mounted shelters. In this paper, by selecting and comparing different materials, using multi-layer composite materials to design the military vehicle-mounted shelter. The shelter body comprises a front wallboard, a rear wallboard, a left wallboard, a right wallboard, an upper wallboard and a lower wallboard. Each wallboard comprises an outer mask, a sandwich material layer and an inner mask in sequence from outside to inside; the outer masks and the inner masks are all metal shielding slabs or respectively comprise a metal shielding net, and different structures are used for the sandwich layer to construct a multi
Wang, Lecheng
Moisture absorption behavior and hygrothermal aging life prediction for CFRP adhesive-bonded joints2022-01-038903/29/2022
Effects of moisture absorption on the strength degradation, energy absorption and failure mechanism of CFRP laminates and the adhesive-bonded joints in hygrothermal environment were investigated in this work. Experiments of accelerated moisture absorption, uniaxial tension and three-point bending were performed. SEM observations on the CFRP laminates and the fracture surfaces of the CFRP bonded joints were conducted. Strength degradation and failure mechanism induced by moisture absorption were discussed in detail. The results showed that the strength degradation in tension and in three-point bending of the CFRP laminate due to moisture absorption reached 7.4% and 17.1%, respectively. Different response of CFRP laminate and adhesive layer to the moisture determined the failure mode of the adhesive-bonded joints. Suitable match of CFRP laminate and adhesive was very important to make the failure mode of the joint under control.
Xu, Xianghe, Yu, HaiYan, Xing, Ping
Design and Optimization of an Electric Car Chassis and Body using Structural Analysis and CFD 2022-01-033903/29/2022
The transition from traditional gasoline-powered automobiles to electric vehicles (EVs) has taken time, two major challenges of engine- powered vehicles are greenhouse gas emissions and fuel economy. Electric cars require less maintenance. A lot of money can be saved while also helping the environment. In today's world, working with lightweight materials have emerged as a key area for improvement in the automotive industry. The most efficient method for increasing power output is to reduce the weight of vehicle components. Composite materials have benefited greatly from research and development because they are stronger, more recyclable, and easier to integrate into vehicles. The primary goal of this research is to design the body and chassis frame of a two-seater electric car. A CFD analysis was performed to determine the drag coefficient of the body along with structural analysis to obtain the frontal impact and torsional rigidity of the chassis to develop an effective electric car
Aiyan, Mohammed, Raghav S, Sanjay, Sagar, S Sumanth
Residual Stress Prediction of a Thermoformed Carbon Fiber Reinforced Polymer Structure Through a Novel Manufacturing to Response Pathway2022-01-032103/29/2022
Thermoforming of thermoplastic-based continuous carbon fiber reinforced polymer (CFRP) offers major advantage in reducing cycle times for large scale productions, but it inevitably induces certain undesirable effects in the formed parts. One such effect is residual stress. For a complex CFRP structure, the magnitude and state (tension/compression) of the residual stress could vary at different locations on the part. Several researchers have developed a number of techniques to experimentally measure the magnitude of these residual stresses, which have shown that these residual stresses could have considerable impact on the mechanical performance of complex CFRP structures, especially developed using thick laminates. However, the degree of impact of the residual stresses on the structural performance of the part still represents a knowledge gap. Experimental investigations could be performed to study the impact of residual stresses on mechanical performance but they are tedious and time
Limaye, Madhura, Pradeep, Sai Aditya, Kothari, Anmol, Agha, Akshat, Li, Gang
Decoding Genuine Ceramic Pad Formulations- Materials and Processing2021-01-127710/11/2021
The need to develop genuine ceramic composites for PV applications arose to overcome the challenges associated with traditional semi-metallic pads. The main focus is to achieve better performance, low noise, better pad and rotor wear, and low dust compared to semi- metallic pads. In general, brake pads convert kinetic energy to thermal energy through friction, and operating temperature in semi-metallic brake pads is higher due to the presence of steel having high thermal conductivity. Over the last decade, the customer preference has moved over to ceramic pads due to light coloured pad surface, low rotor and pad wear and low dust compared to semi-metallic pads. The traditional steel has been replaced by Aramid, engineered ceramic fibre, potassium titanate (TISMO D), lapinus fibre (RB 250) to impart similar/better performance. The current work investigates the characterisation of genuine ceramic and semi-metallic composites. Three genuine ceramic and one semi-met composite have been
Tomar, Bharat, Ali, Sharafat, Ellis, Keith, Choudhary, Yogesh
A Molecular Dynamics Study of Tribological Properties of Silicon Carbide as a Metal-Free Friction Material2021-01-128410/11/2021
Friction materials containing metal ingredients used in the automotive industry can cause unfavorable environmental impacts. Existing laws and regulations require heavy metals in brake pads to be phased out of production. Substitutions for metals in friction materials, however, may introduce operational safety issue and other unforeseen problems. In the current study, a molecular dynamics model based on LAMMPS has been developed to study the effect of material composition, density, and geometric configurations on the tribological, mechanical, and thermal properties of silicon carbide under various contact conditions at the atomic level. Simulations which incorporate interfacial contact between surface asperities were performed to predict the elastic modulus, thermal conductivity, wear rate, and coefficient of friction. The resulting predicted properties may help enhance the performance of engineered metal-free friction materials against thermal-mechanical failures. The following
Zhang, Yizhan, LeNeave, Cortney, Yi, Yun-Bo
Effect of Material Anisotropy on Thermal-Mechanical Instabilities in Metal-Free Friction Materials2021-01-128910/11/2021
An anisotropic ceramic matrix composite (CMC), which consists of a silicon carbide (SiC) based ceramic matrix reinforced with carbon (C) fibers, is considered as a metal-free friction material replacement in brake and clutch applications. The fibers are assumed to have a circular cross-section, arranged unidirectionally and packed in a rectangular array without the presence of voids. The rule of mixture showed the C-SiC composite to be transversely isotropic with the circumferential plane as the plane of isotropy. A set of parametric studies have been performed to computationally investigate the dominant parameters that affect thermal-mechanical instabilities. It is found that the chance of thermal buckling in the friction disc can be minimized by reducing the elastic moduli in the radial and circumferential directions, or by reducing the coefficient of thermal expansion in the same directions. Meanwhile, the material properties in the axial direction do not have a significant effect
Shaahu, Joseph-shaahu, Koranteng, Kingsford, Yi, Yun-Bo
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
Mechanical property optimization of tamarind fruit fiber for lightweight structural composites applications2021-28-027010/01/2021
Natural fibers are dominating many composite industries due to their unique properties such as reusability, biodegradability, and environmental safety. Tamarind fruit fiber (TFF) stands out among the various fruit fibers and has been discovered in large quantities being discarded from the food processing industries. However, many natural fibers are extracted from their sources, which results in deforestation and environmental degradation. As a result, in today's world, recycling waste into new useful products is the primary concern in any field of engineering. In light of this, the current study used TFF obtained from agro industries and processed into fibers, which were then mixed with an unsaturated polyester matrix to create a natural composite material. Furthermore, by considering process parameters and their levels for conducting experiments, an orthogonal array has been achieved using Taguchi's design approach. The effect of different fiber diameters in relation to various gauge
Joseph Selvi, Binoj, Natarajan PhD, Manikandan, Pattipati Chinna PhD, Krishnamachary, Karu Clement PhD, Varaprasad, Pasupuleti, Thejasree, Justin Abraham Baby PhD, Sajin
Assessment of tribological characteristics of stir cum Squeeze cast AlSi7Mg with 3wt % MoS2 and xwt % Flyash Hybrid Metal Matrix Composites2021-28-026010/01/2021
This research work aims to investigate the effect of SiCp and MoS2 lubricant particles on the tribological properties of AlSi7Mg alloy fabricated through stir casting and stir cum squeeze casting process. AlSi7Mg alloy is a supreme favourable industrial aluminium alloy owing to its exceptional casting ability, corrosion resistance and good strength to weight ratio. Stir casting is an effective and capable processing route for making aluminum composites with enhanced properties. Further to obtain improvised properties and pore-free structure aluminium matrix composites were fabricated through stir cum squeeze casting processing route. During the experimental investigation, AlSi7Mg alloy reinforced with 3 wt % MoS2 and 0, 5, 10 wt % of flyash is processed through stir casting and stir cum squeeze casting processing route. Tribological responses like wear rate and coefficient of friction were measured using Pin-on-Disc tribometer apparatus under dry sliding condition of load 10, 20, 30
A, Sathishkumar, R, Soundararajan, Siva krishna, Sneha, Ranjan prabakaran, Badma Rani
Evaluating the mechanical behavior of fused deposition modeling parameters of Raster angle and Layer thickness effects on as-built and annealed polymer associated composites2021-28-028310/01/2021
Fused deposition Modeling (FDM) is one of the 3D techniques which are mainly used to fabricate the three-dimensional object directly and it is more economical method. The objective of this investigation is to primarily as-build and annealed polymer associated composites of carbon fiber Polyethylene Terephthalate Glycol (CF-PETG) material by FDM with the effect of different raster angle and layer thickness were consider for the prime parameters. The test specimen was prepared by FDM process with different raster angle (00/900, -450, +450, -450+450) and layer thickness (100, 400 microns) with other parameters were kept constant. The study of the mechanical properties such as hardness, tensile and impact test of the as-built and annealed CF-PETG were studied. The best results obtained for annealed specimens printed with raster angle of 00/900 and layer thickness of 100 microns produced more influence in all the mechanical properties. The high strength printed samples were suggested for
Ari Gowder Ravi Kumar, Sivanesh, R, Soundararajan, Dorai, Arivazhakan, Suresh Kumar, Gopinath, Ramesh, Aravind Kumar
Experimental Studies on the performances of Hybrid- Natural Fiber / Powder Strengthened Polymer Composite Structure2021-28-027610/01/2021
This research paper affords the practical investigation of the fabrication of eco based composites. The banana fiber is used as primary and powdered coconut shell is utilized as secondary reinforcements with epoxy resin to structure hybrid composite samples. The fiber weight proportion was kept as constant and the powder weight proportion was varied with five different proportions. Composite laminates were fabricated by hand lay-up method followed by compression moulding process. The manufactured composites had been examined as per the standards of ASTM to estimate the mechanical behaviors such as flexural , tensile, shear and impact strengths. Also the effect of water immersion on the mechanical properties are evaluated in each manufactured sample. The results of the tests show that under mechanical loads, the hybrid composite with coconut shell powder outperforms the unfilled fiber reinforced composite.
Rangasamy, Ramamoorthi, Rengaraj, Jeyakumar, Kaliyaperumal, Balasubramanian, Subramanian, Vignesh, R, Soundararajan
Flexural behavior of hybrid layered composites suitable for automotive structural applications2021-28-021010/01/2021
Electric vehicle is the current trend in automotive industry. A light weight material at affordable cost is preferred for these types of vehicles. Composite is a suitable material for this due to their attractive strength-to-weight ratio. Even though carbon fiber reinforced composites provide very good strength and modulus its usage is limited because of their higher price. Hybrid laminates stacked with glass/carbon/kevlar fiber layer shall provide good strength at lower cost. This work focus on the flexural behaviour of glass fiber reinforced laminates stacked with carbon and kevlar fiber as outer layer. Laminates were prepared by hand lay-up method. Three-point bending test was conducted as per ASTM standard. A significant improvement in flexural modulus and bending resistance was observed for the glass/carbon-epoxy hybrid laminates when compared with the glass-epoxy laminate. The micrographs of the failed specimens are also studied.
A, Arockia Julias, Ponniah Daniel, Jeyakumar, Manohar, D Murali, Muthiah, Thirumurugan, R, Sathish Kumar
Mechanical studies on polycaprolactone based green composite2021-28-024210/01/2021
In the last decade, there was growing interest in the use of green composites because of their environment friendly nature, improvement in mechanical & chemical properties, better process ability and low cost. In this work, short sisal fiber is reinforced in (PCL) matrix to produce a green composite that is degradable. This work aims to reduce the plastic waste and extend the life span of biodegradable products used in our routine life. This experimental study on mechanical properties of PCL based composites is focused on testing the tensile, impact, and hardness behavior of the material with different weight fractions. These tests were conducted as per standards. The data obtained are compared to identify the best possible composition of PCL and sisal. This PCL based composites shall find applications in packaging industry and consumer goods that have less service temperature.
A, Arockia Julias, Kareem, Abdul, A, Ganesh Raman, Ponniah Daniel, Jeyakumar, Krishnasamy, Prabu
Microstructural changes and Mechanical properties upgrading over Friction Stir Processing strategies on A356 alloy with tungsten nano particle surface layer composites2021-28-026910/01/2021
Friction stir processing (FSP) is a typical process for refinement changes of microstructure, upgradation of material’s mechanical properties and fabricating of surface layer composites. The effect of cast A356 surface composites were fabricated through Friction Stir Processing (FSP) route to appraise the metallurgical and mechanical properties were considered in the present research study. The three combination of test samples of FSP’ed cast A356 alloy, FSP’ed cast A356 FSP with tungsten nano particle addition (5 and 10 vol%) were considered to fabrication under fixed parametric conditions like tool rotational speed of 1000 rpm, load acting 9 kN, tool travel speed of 20 mm min−1 through four number of tool travel passes respectively. Obtained FSP’ed samples were exposed to microstructural, tensile strength tests and fracture surface morphology analysis were carried out to record the responses. It was observed in stir zone microstructure that the FSP parameters have affected the
R, Soundararajan, Prince Edward, Jerald Immanuel, Venkitkumar, Nishanth, Aruchamy, Sathishkumar
Tribological evaluation of organic frictional composites filled with various nano- solid lubricants2021-28-025910/01/2021
Incorporation of organic fibers originate from plants in polymer composite is not new as they provide eco-friendly lighter composite and it have gained attention over a period of time because of the specific applications. The augmenting demanded by automotive sectors for wear and frictional areas where the conservation of energy is concerned is expected one with the addition of nano – solid lubricants. Our aim is to highlight the possibility of organic basalt fiber reinforced polymer composites along with three possible combination of nano – solid lubricants like graphite/graphene/ molybdenum disulfide was chosen and to fabricate tribo-materials through hot press technique. The outcome of the tribological tests (by varying load and sliding velocity) indicates that the responses of these three organic fiber based polymer composites have been effectively modified by nano-solid lubricants leading to significant enhancement as tribo materials is highlighted in higher level of load and
R, Soundararajan, Javid Firnas, Sait, Naveen raj, Nandakumar, pradeep s, sabapathy
Evolution of A356 with flyash composites on metallurgical mechanical and tribological behaviour under dry and wet conditions2021-28-027210/01/2021
Among all metal matrix composites, A356 is the most applicable matrix due to its low density and exhibits nominal strength with soft nature. This proposed study is concerned with examination of mechanical and tribological behaviour of virgin A356 alloy and A356 reinforcement with 10wt.% power plant waste flyash particles composites were processed by liquid metallurgy stir casting technique. The fabricated composites expose enhanced higher hardness and compare the virgin A356 alloy due to presents of flyash particles in the matrix. The wear and friction behaviour of casted samples was tested in pin on disk tribometer apparatus under dry and wet sliding environment at the presence of lubricant (SAE 80W-90) by varying sliding load of 10N-40N and sliding velocity of 1-3 m/s respectively. Wear rate increase with the increasing load and sliding velocity. The usage of lubricant tends to decrease the wear rate by reducing the friction when compared to dry sliding method. This was ascribed due
R, Soundararajan, A, Sathishkumar, Kalaiarasan, Kaviyarasan, Kumar K, Sathish
Tribological Behavior of Thermal and Mechanical Composite Reinforced Sisal Characteristics and Influence SiC Filling Material2021-28-027710/01/2021
In order to investigate the possible use of normal capital, we have tried by hand to manufacture sisal fibre polymer composites. Natural fibre composites are reusable, low-cost and biodegradable. Simple source, lesser compactness, superior basic property, lower quality, acceptable physical and mechanical properties, non acidic in environment, make them a good-looking biological substitute for glass, carbon or other artificial fibres. The outcome of SiC on the physical and mechanical properties of organic sisal composite materials is studied in this work. The composite was manufactured with and without SiC, mixing natural sisal fibre with polyester as a reinforcement medium. The investigational results showed that the tensile force of the mixture with 12 % SiC was 2.52 times better than that of the composite devoid of SiC. The collision strength of the 12% SiC merged is 1.72 times higher than that of the SiC pure polyester composite. The physical properties deliberate include thermal
RAJU, GANESAMOORTHY, NATARAJAN, Balaji, Chakaravarthy, Ezilarasan, Samikannu, Poovaragan, R, Soundararajan
Carbon Fiber Fabric and Epoxy Resin Wet Lay-Up Repair Material Part 5 - Carbon Fiber Fabrics, Plain Weave, 193 g/m2, and Epoxy ResinAMS2980/5A (Current)09/24/2021
This Material Specification defines the requirements of carbon fiber fabric and epoxy resin systems used for wet lay-up repair of carbon fiber reinforced epoxy structures, qualified according to AMS2980/1 and AMS2980/2. Unless otherwise specified by the drawing, the order or the inspection schedule, the present specification shall be used in conjunction with the referenced documents.
AMS CACRC Commercial Aircraft Composite Repair Committee
Effects of Environmental Factors on Flexural Properties of Long Fiber Reinforced Polymer Composite2021-26-025709/22/2021
Environmental regulation, operating cost reduction and meeting stringent safety norms are the predominant challenges for the automotive sector today. Automotive OEMs are facing equally aggressive challenges to meet high fuel efficiency, superior performance, low cost and weight with enhanced durability and reliability. One of the key technologies which enable light weighting and cost optimization is the use of fiber reinforced polymer (FRP) composite in automotive chassis systems. FRP composites have high specific strength, corrosion and fatigue resistance with additional advantage of complex near net shape manufacturing and tailor made properties. These advantages makes FRPs an ideal choice for replacing conventional steel chassis automotive components. However, FRP’s face challenges from operating environment, in particular temperature and moisture. In the present study, the effect of environmental variables like temperature, moisture on properties of FRP was studied on epoxy based E
Polisetti, Venkata Sumanth, Shende, Deodatta Anil, Varatharajan, Senthilkumaran, Ponkshe, Shripadraj
Design Development and Testing of Light-weight FUPD using Composites Material2021-26-024509/22/2021
With the increasing need for developing fuel-efficient and high-performance vehicles, Light weighting has become a very important aspect in automotive industry. Hence conversion of the existing metal components to composites is gaining momentum. Composite materials are much lighter than metals and offer many advantages such as fuel efficiency, corrosion resistance and improved life which has resulted in the increased usage of composite materials. Front Under-run Protection Device (FUPD) is a protective device which is fitted on the front side of a truck which prevents the vehicle in front from under-running below the truck and also absorbs impact energy in case of a collision. This paper discusses the design, development and Certification from ARAI of the lightweight composite Front Under-run Protection Device (FUPD). It has resulted in 33.33% weight reduction compared to the earlier metal component. The light-weight composite FUPD withstands loads of 80 kN and 160 kN as per the
Srivastava, Sanjay, Dravid, Nikhil
Test Method for Determining Cold Cracking of Flexible Plastic MaterialsJ323_202109 (Current)09/15/2021
This SAE Recommended Practice is applicable for determining the cold characteristics of flexible plastic materials, as applicable. It consists of three different methods for determining low-temperature properties of materials depending on type of material and end use. The method used shall be as specified by the contractual parties.
Textile and Flexible Plastics Committee
Automotive Engineering: September 202121AUTP0909/01/2021
Weaving a new future for composites In a shift perhaps as prolific as steel to aluminum, woven plastics may finally bring the magic of composites to cost-effective mass-production. New composites target EV applications No longer a low-volume play, the latest composite materials offer EV developers new options for lightweighting, thermal management and structures. Acura TLX is Honda's new body-build benchmark All-new for 2021, Acura's midsize sport sedan gets an exclusive platform to go with its structural, materials and dynamic advancements. Body development leader Jeremy Lucas explains. Schaeffler builds an e-motor powerhouse Armed with state-of-the-art manufacturing and a history of innovation, Schaeffler Group is attacking the e-mobility space, says Daniel Sayre. Editorial EV bafflers, surprises and ironies Altair honors weight-saving innovations Finding failure inside lithium-metal batteries GM puts its new 2023 Corvette V8 on a different 'plane' SAE Standards News New ISO-SAE
Development Work for a New Damping Standard SAE J31302021-01-112208/31/2021
Standards organizations develop standards depending on the need in the market place. With the change in vehicle design, lightweighting structures, and body panels made out of aluminum and composites, SAE’s Acoustical Materials Committee is developing a new damping standard. This standard is also very suitable in determining the damping performance of materials used in the off-highway applications, where the thickness of the steel body panel is much greater than in the automotive application. The general methodology of this standard is based on the mechanical impedance measurement method and has been developed with the general consensus of automotive engineers, suppliers, and independent test laboratories. This method is essentially based on the fact that a bar is excited at the center by a shaker. The force exerted by the shaker and the corresponding vibration is measured at that point to determine the frequency response function of the mechanical impedance signal. This paper discusses
Saha, Pranab
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