Browse Topic: Ferrous metals

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Evaluation of Shear Trim Edge in HSLA Steel for Automotive Application2026-26-02861/16/2026
Quality of the Shear Trimmed edge of HSLA 550 steels is significantly affected by process variations such as Shear Trimming Clearance, trim tolerance, burr height and clamping force. All these parameters largely influence the characteristics of the Shear Affected Zone, a region on sheet metal where it undergoes deformation during the trimming process. The Shear Affected Zone is predominantly vulnerable to failure due to work hardening and the effects of strain rate, induced by the tonnage during the trimming operation. To assess the edge ductility of these materials, Tensile, Fatigue Strength, Die Punch Clearance, Roughness and Hardness Tests are carried out. These tests are crucial for applications that demand high formability and resistance to edge failure. Virtual simulation of edge trimming operation using elastoplastic material models in LS-Dyna have been performed to gain insights into burr formation and damage evolution during shearing. These simulations act as a precursor to
Thota, Badri Vishal, Kashyap, Amit, Bhuvangiri, Jaydev
Optimization of the Rodip CED Process Suitability through Strategic Fixture System for Enhanced Hood Gap and Flushness Control in Automotive Manufacturing2026-26-04861/16/2026
The Ro-dip Cathodic Electrodeposition (CED) process is latest technology used by Automotive Manufacturers for higher quality corrosion protection in new generation Automobiles. This process involves multiple 360-degree rotation of automotive body in white (BIW) which exert higher hydrostatic forces on large surface panels like Hood. For maintaining consistent gaps & flushness control at vehicle level, it is important to safeguard the dimensional stability of light weight (crash performance sensitive) steel Hood panel while undergoing through this CED process. This study investigates the enhancement of hood panel alignment through strategic optimization of support rod placement and quantity within the Ro-dip CED system. By conducting experimental trials and computational simulations, the research identifies critical deformation points and evaluates the impact of varying support rod configurations on dimensional stability. The outcome results demonstrate that positioning support rods at
Tile, Vikrant, Unadkat, Siddharth, ASKARI, HASAN, Jadhav, Devidas
Hydrogen Embrittlement in Galvanized High Carbon Steel Components of Automotive Seat Slider Assembly2026-26-03021/16/2026
This research paper investigates the failure of an isolator clip used in the seat slider assembly, which guides and restricts the sliding motion of the tooth bracket within the seat. The component is made of C80 high-carbon spring steel, known for its high strength. According to the manufacturing process details, zinc plating was applied to the component for corrosion protection, as confirmed by EDS analysis. A fractographic examination of the failed part revealed a brittle, intergranular fracture morphology with visible cracks. Certain areas also exhibited micro-void coalescence, indicating a dimpled fracture surface. The primary failure mode was intergranular (IG) fracture. The delayed fracture was attributed to intergranular fracture mechanisms, micro-void coalescence, and the high strength of the steel, which made the component susceptible to hydrogen embrittlement. Hydrogen embrittlement occurs when hydrogen atoms become trapped along the grain boundaries, where they form hydrogen
Saindane, Mehul Kishor, BALI, SHIRISH
Improvement study of Style steel wheel durability in Multiple pothole impacts2026-26-05391/16/2026
This study focuses on improving the durability of steel wheel rims subjected to Multiple Pothole which is commonly found in Indian village roads - a critical scenario affecting vehicle safety and wheel lifespan. Initial steel wheel designs often face significant deformation or failure under repeated strikes and resulting in tyre air loss due to wheel bend, prompting the need for enhanced performance standards. In this research, a combination of finite element modelling, experimental impact testing, and material optimization strategies were employed to assess and improve the structural integrity of steel rims. Key parameters such as rim profile geometry & material composition were systematically varied to evaluate their influence on impact resistance. Results demonstrate that strategic design modifications and material enhancements can significantly increase the rim's ability to absorb energy and resist bending without substantial weight penalties. The findings offer practical
DEsigan, Lakshmipathy, P, Praveen, K, CHANDRAMOHAN, C, Santhosh
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
Niobium Alloyed Brake Disc for reduced NVH and emission control2026-26-02851/16/2026
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
A Study on the Microstructural Changes and Corrosion Behavior and Mechanical Properties in Stainless Steel Welds with Single Versus Double Stabilized Welding Wires2026-26-02881/16/2026
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 net2026-26-02901/16/2026
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
Balancing global and local formability properties through Nb microalloying2026-26-03031/16/2026
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
Experimental Study on the Role of Hole Expansion Ratio in Enhancing Crashworthiness of Advanced High Strength Steel2026-26-02951/16/2026
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 Vehicles2026-26-01861/16/2026
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
Steel, Corrosion Resistant, Sheet, Strip, and Foil, 19Cr - 9.5Ni (304), Cold Rolled, 125 ksi (862 MPa) Tensile StrengthAMS5501G (Current)12/8/2025
This specification covers a corrosion-resistant steel in the form of sheet, strip, and foil 0.005 inch (0.13 mm) and over in nominal thickness (see 8.4).
AMS F Corrosion Heat Resistant Alloys Committee
Hose Assembly, Polytetrafluoroethylene, Cres Reinforced, 400 °F, 3000 psi, Lightweight, Beam Seal, Straight to 90°AS1911D (Current)11/26/2025
No scope available
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Steel, Bars, Forgings, and Rings 0.95Cr - 0.20Mo (0.28 - 0.33C) (SAE 4130) AMS6370S (Current)11/25/2025
This specification covers an aircraft-quality, low-alloy steel in the form of bars, forgings, flash welded rings, and stock for forging or flash welded rings.
AMS E Carbon and Low Alloy Steels Committee
Steel Bars, Forgings, and Tubing 1.8Ni - 0.25Mo (0.38 - 0.43C) (4640) AMS6312L (Current)11/25/2025
This specification covers an aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock.
AMS E Carbon and Low Alloy Steels Committee
Steel, Corrosion-Resistant, Sheet and Strip, 19Cr - 9.2Ni (304), Cold Rolled, Full Hard, 185 ksi (1276 MPa) Tensile StrengthAMS5913D (Current)11/25/2025
This specification covers a corrosion-resistant steel in the form of sheet and strip over 0.005 inch (0.13 mm) in nominal thickness (see 8.6).
AMS F Corrosion Heat Resistant Alloys Committee
Steel, Corrosion-Resistant, Sheet and Strip, 19Cr - 9.2Ni (304), Cold Rolled, 3/4 Hard, 175 ksi (1207 MPa) Tensile StrengthAMS5912D (Current)11/25/2025
This specification covers a corrosion-resistant steel in the form of sheet and strip over 0.005 inch (0.13 mm) in nominal thickness (see 8.6).
AMS F Corrosion Heat Resistant Alloys Committee
Steel, Corrosion-Resistant, Sheet and Strip, 19Cr - 9.2Ni (304), Cold Rolled, 1/2 Hard, 150 ksi (1034 MPa) Tensile StrengthAMS5911D (Current)11/25/2025
This specification covers a corrosion-resistant steel in the form of sheet and strip over 0.005 inch (0.13 mm) in nominal thickness (see 8.6).
AMS F Corrosion Heat Resistant Alloys Committee
Steel, Corrosion-Resistant, Sheet and Strip, 18Cr - 8Ni (301), Cold Rolled, 3/4 Hard, 175 ksi (1207 MPa) Tensile StrengthAMS5902E (Current)11/25/2025
This specification covers a corrosion-resistant steel in the form of sheet and strip over 0.005-inch (0.13-mm) in nominal thickness (see 8.6).
AMS F Corrosion Heat Resistant Alloys Committee
Steel, Corrosion Resistant, Bars and Wire, 19Cr - 10Ni (304), High Yield Strength, Solution Heat Treated and Cold WorkedAMS5857E (Current)11/25/2025
This specification covers a corrosion-resistant steel in the form of cold-worked bars and wire up to 1.750 inch (44.45 mm) inclusive, in nominal diameter or least distance between parallel sides (see 8.4).
AMS F Corrosion Heat Resistant Alloys Committee
Steel, Corrosion and Heat Resistant, Flat Wire 15Cr - 25.5Ni - 1.2Mo - 2.1Ti - 0.006B - 0.30V 1800 °F (982 °C) Solution Treated, Cold Drawn or Cold Rolled and Aged, Consumable Electrode Remelted AMS5810C (Current)11/25/2025
This specification covers a corrosion and heat resistant steel in the form of flat wire.
AMS F Corrosion Heat Resistant Alloys Committee
Steel, Corrosion Resistant, Bars, Wire, and Forgings 5.8Mn - 17Cr - 5.8Ni - 2.0Cu - 0.26S Free Machining, Solution Heat Treated AMS5762H (Current)11/25/2025
This specification covers a free-machining, corrosion-resistant steel in the form of bars, wire, forgings, and forging stock.
AMS F Corrosion Heat Resistant Alloys Committee
Steel, Corrosion and Heat-Resistant, Bars and Forgings 15.5Cr - 4.5Ni - 2.9Mo - 0.10N Consumable Electrode Remelted Solution Heat Treated, Sub-Zero Cooled, Equalized, and Over-Tempered AMS5743L (Current)11/25/2025
This specification covers a corrosion and heat-resistant steel in the form of bars, forgings, and forging stock. These products have been used typically for parts requiring oxidation resistance and high strength up to 800 °F (427 °C) and where such parts may require welding during fabrication, but usage is not limited to such applications.
AMS F Corrosion Heat Resistant Alloys Committee
Steel, Corrosion Resistant, Bars and Wire, 18Cr - 9Ni (303F), Free Machining, High Yield Strength, Solution Heat Treated and Cold WorkedAMS5738F (Current)11/25/2025
This specification covers a free-machining, corrosion-resistant steel in the form of cold-worked bars and wire up to 1.750 inches (44.45 mm) inclusive, in nominal diameter or least distance between parallel sides (see 8.5).
AMS F Corrosion Heat Resistant Alloys Committee
Steel, Corrosion and Heat-Resistant, Welding Wire 19Cr - 12.5Ni - 2.5Mo AMS5696F (Current)11/25/2025
This specification covers a corrosion and heat-resistant steel in the form of welding wire.
AMS F Corrosion Heat Resistant Alloys Committee
Steel, Corrosion-Resistant, Laminated, Sheet, Surface BondedAMS5500H (Current)11/25/2025
This specification covers a corrosion-resistant steel in the form of laminated sheet.
AMS F Corrosion Heat Resistant Alloys Committee
Iron-Nickel Alloy, Strip, 49Fe - 5.3Cr - 42Ni - 2.5Ti - 0.55Al, Solution Heat Treated, Cold Rolled, 10% ReductionAMS5223H (Current)11/25/2025
This specification covers an iron-nickel alloy in the form of strip 0.020 to 0.1874 inch (0.51 to 4.760 mm), inclusive, in nominal thickness (see 8.6).
AMS F Corrosion Heat Resistant Alloys Committee
Iron-Nickel Alloy Strip, 49Fe - 5.3Cr - 42Ni - 2.5Ti - 0.55Al, Solution Heat TreatedAMS5221G (Current)11/25/2025
This specification covers an iron-nickel alloy in the form of strip 0.020 to 0.250 inch (0.51 to 6.35 mm) inclusive, in thickness (see 8.8).
AMS F Corrosion Heat Resistant Alloys Committee
Landing Gear Component Heat DamageAIR5913B (Current)11/11/2025
The purpose of this report is to outline types of in-service heat damage that have been observed in high strength steel landing gear components, with an emphasis on a particular type that is referred to as “Ladder Cracking” which can develop in landing gear shock struts. The report discusses how ladder cracking can be detected visually and evaluated by non-destructive inspection methods, and how it can be repaired at overhaul with the prior approval of the Original Equipment Manufacturer. This report also describes the use of a bearing material that has resolved this problem without introducing other problems. Examples of other types of service induced heat damage are also discussed.
A-5B Gears, Struts and Couplings CommitteeNEW
Plating, Brush, Cadmium Corrosion Protective, Low Hydrogen EmbrittlementAMS2451/4E (Current)11/10/2025
This specification establishes the requirements for brush plating of cadmium by electrodeposition.
AMS B Finishes Processes and Fluids Committee
Automated Gaseous Nitrocarburizing Controlled by PotentialsAMS2759/12C (Current)11/10/2025
This specification covers the requirements for producing a continuous white layer with controlled extent of porosity by means of a gaseous process, automatically controlled to maintain set values of the nitriding and carburizing potentials that determine properties of the nitrocarburized surface. Automatic control is intended to ensure repeatability of nitrogen and carbon content of the white layer which influences properties such as wear and corrosion resistance, ductility and fatigue strength.
AMS B Finishes Processes and Fluids Committee
TEE ASSEMBLY, FLARED TUBE, RETAINED NUT ON RUN, FOR SEAL RINGAS4302A (Current)5/2/2025
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
A review of warm forming for steels: History, Methodology and Emerging trends2025-01-88144/1/2025
Many manufacturing techniques and process modifications have been implemented over the years to improve the formability of sheet metals. Warm forming of sheet metals is one such established method. However, it is more commonly and successfully applied to aluminum grades. The reevaluation of less-used metal forming technologies, such as warm forming and sheet hydroforming for steel, is a response to the challenges posed by competitive processes like large castings and the geometry requirements of new BEV parts. By understanding the effects of elevated temperatures (below recrystallization temperatures) on different steel grades and the impact of various heating methodologies, the industry can adapt and optimize these proven techniques for modern applications. This paper is a comprehensive summary of the effect of elevated temperatures on various grades of steel. Different heating techniques, their cycle times and effects on final forming feasibility is contrasted. The effect of
Kella, Caroline, Wormald, Tom, Gatts, Joshua
Iron and Steel Castings Engineering GuideB-ASM-0552/28/2024
This engineering guide, an accompanying guide to Aluminum Castings Engineering Guide (ASM International, 2018), explains the interactions of product design (for function and manufacturability), materials engineering (for the best choice of alloy and microstructure), and process engineering practices (to achieve the properties and integrity of a component at the most comprehensive cost).
Effect of spot weld parameter on HAZ of advanced high strength steel joint.2024-26-01871/16/2024
To meet different target of light-weighting, lower fuel economy, crash safety and emission requirement, advanced high strength steel (AHSS) is commonly used in automotive vehicles and has become popular now a days. AHSS material up-to 1500 MPa is commonly used for structural components and major reinforcement of automotive BIW. Manufacturing of AHSS material requires precise control of chemical composition, and subsequent rolling and heat treatment to get optimum combination of required phases In most of the AHSS material microstructure, martensite is present along with ferrite or other phases. Hot stamp steel with strength level 1500 MPa strength also have martensite phase in microstructure after press hardening. However during heating and cooling cycle in resistance spot welding, martensite phase tempering affects hardness at Heat Affected Zone (HAZ). Softness at HAZ zone lower downs shear and tensile strength of joint which impacts fatigue properties of the joint and energy
Jain, Vikas, Misal, Swapnali, Paliwal, Lokesh
INTEGRATION OF SEAT-BELT WEB-GUIDE FUNCTIONALITY IN TRIM PART2024-26-00181/16/2024
Restraint systems in automotives are inevitable for the safety of passengers. Seat belts are one such restraint system in automotives that prevent drivers and passengers from being injured during a crash by restraining them back. Seatbelt on automotives has interface with Body-in-white (henceforth called as BIW) and Trim parts in-order to serve its purpose at vehicle level. One such interface part of seat belt is the web guide, which assists and ensures the nylon web’s smooth motion at different seat track positions. Web-guides on automotives ensure the flawless motion of seat belt web at pillar trim areas. In this paper, we are discussing about alternate ways of assisting the seat belt web without the web-guide as a separate part In-order to assist and ensure the motion of nylon web in its trajectory, we have extended the flange of the pillar trim involved. The paper throws light on the advantages of using an extended trim flange as web-guide for seat belt web instead of a separate
D, GOWTHAM, bornare, harshad, GANGAPURAM, SURESH, Deoli, Manish, RITESH, KAKADE, sai, Konduru, Kakani, Phani Kumar
USUALLY UNOBSERVED REFINEMENTS OF AUTOMOBILE CONSTRUCTION0800031/1/2024
ELLSWORTH, JOHN MAGEE, FAY, THOMAS J.
Comprehensive Evaluation of Logging Frameworks for Future Vehicle Diagnostics2023-01-12236/26/2023
More and more applications (apps) are entering vehicles. Customers would like to have in-car apps in their infotainment system, which they already use regularly on their smartphones. Other apps with new functionalities also inspire vehicle customers, but only as long as the customer can utilize them. To ensure customer satisfaction, it is important that these apps work and that failures are found and corrected as quickly as possible. Therefore, in-car apps also implicate requirements for future vehicle diagnostics. This is because current vehicle diagnostic methods are not designed for handling dynamic software failures of apps. Consequently, new diagnostic methods are needed to support the diagnosis of in-car apps. Log data is a central building block in software systems for system health management or troubleshooting. However, there are different types of log data and log environment setups depending on the underlying system or software platform. Depending on that, the creation of
Bickelhaupt, Sandra, Hahn, Michael, Nuding, Nikolai, Morozov, Andrey, Weyrich, Michael
Design of a Robust Optimal Multivariable Control for a Steer-by-Wire System2023-01-12186/26/2023
On the way to highly automated and autonomous driving, a robustly designed steering system is a key component. Therefore, the proposed article will present a new control approach for modern steer-by-wire systems. The novel approach consists of a true multivariable control for the driver´s steering torque and the rack position simultaneously using the requested torques of the downstream (SRU) and upstream (SFU) motor as control variables. Here, the plant model is a detailed model of a steer-by-wire system with nine degrees of freedom (see Fig.1). For the control design, an optimal reduced model is derived. The reduced plant model is linearized and augmented by linear models for the reference and disturbance environment of the steer-by-wire system and by a linearized model for the complete feeling generator computing the requested steering torque. The feeling generator consists of a rack force feedback, an active damping and an active steering wheel return. For this augmented model, a
Irmer, Marcus, Degen, René, Nüßgen, Alexander, Thomas PhD, Karin, Ruschitzka PhD, Margot, Henrichfreise PhD, Hermann
Technical evaluation of the obstacle detection for autonomous shuttle buses2023-01-12276/26/2023
With the law on autonomous driving and the associated ordinance, it has been possible in Germany since June 2022 to grant operating permission to vehicles with autonomous driving function and to admit them to road traffic. For public transport, autonomous shuttle buses offer the opportunity to maintain the existing service despite a shortage of personnel and to close gaps in supply. The safety of vehicle occupants, other road users and third parties is a key concern in the operation of autonomous shuttle buses. As part of the project "Reallabor für den Automatisierten Busbetrieb im ÖPNV in der Stadt und auf dem Land" ("Reallabor for Automated Bus Operation in Public Transport in Urban and Rural Areas", or RABus for short), which is funded by the Ministry of Transport Baden-Württemberg, the operational reliability of autonomous shuttle buses in public transport is being scientifically investigated. In the implementation of autonomous driving, obstacle detection/avoidance is a safety
Gao, Kun, Weinrich, Ulrike, Riemer, Thomas, Reuss, Hans-Christian
Design of a Model-Based Optimal Multivariable Control for the Individual Wheel Slip of a Two-Track Vehicle2023-01-12196/26/2023
The concept of autonomous driving has become increasingly relevant. This is why innovative drive concepts for motor vehicles need to be developed. Therefore, a model-based optimal multivariable control for the wheel slip is presented in this paper. This allows to specify the slip, and thus the tire force, individually for each wheel. The plant model consists of a planar and stiff multibody two-track model of a vehicle, a complex tire model as well as a simple air resistance and motor model. In addition, the contact forces of the individual wheels are calculated dynamically. A special feature of the multibody model is that the vehicle's position variables are defined by integrating the velocity variables. The linearized model derived from the nonlinear model is used to design a linear optimal static state space controller (LQR) including reference and disturbance feedforward. The contact point velocities of the tires are defined as the controlled variables, since they are proportional
Irmer, Marcus, Rosenthal, Robert, Nüßgen, Alexander, Degen, René, Thomas PhD, Karin, Ruschitzka PhD, Margot
Concept for an Approval-focused Over-The-Air Update Development Process2023-01-12246/26/2023
The idea of keeping a vehicle safe and secure throughout its whole life cycle, as well as having the opportunity to add functionality after initial delivery, is the key motivation behind automotive software updates. Today, safety or security issues that appear after vehicle delivery need to be resolved by starting a recall campaign. These campaigns require the vehicle user to visit a car repair workshop to get an update. Over The Air (OTA) software updates, being location-independent, can pave the way for higher update frequencies and more efficiency regarding customer satisfaction, resource consumption as well as safety and security. In this paper we analyze requirements for OTA updates phrased in various standards and regulations as well as in existing development and type approval processes. Prevailing challenges for OTA updates are extracted to identify necessary activities and artifacts within the procedure. Based on that a concept for the approval and execution processes of OTA
Henle, Jacqueline, Gierl, Mona, Guissouma, Houssem, Müller, Felix, Ramesh, Goutham Bharadwaj, Sax, Eric
A Holistic Approach For Near Zero Emission Diesel Vehicles Using A Pre-Turbo-Catalyst-System – Ready For EU 72023-01-12116/26/2023
This work shows the newest results of a near-series Pre-Turbo-Catalyst (PTC) system reaching lowest emissions for electrified diesel passenger cars to address future emission legislation. The PTC system is developed using a state-of-the-art tool chain containing 1D & 3D simulation approaches and testing near-series exhaust gas aftertreatment systems under real-driving boundary conditions. The innovative concept of an SCR PTC and a PTC bypass path solve the challenge of a thermal handshake between PTC and underfloor SCR System as well as the challenge of a particular filter regeneration. The development of adaptive PTC bypass path operation strategies based on exhaust gas and catalyst conditions enables lowest NOx and NH3. Using this concept, near-zero emissions can be reached in a wide range of operating scenarios while sustaining full drivability and highest efficiency. Advanced catalyst technologies enable a high emission conversion and lowest secondary emissions. These results have
Conin, Michael, Beidl, Christian, Knaf, Daniel, Fiore, Luis, Kreuz, Joachim
AI-Based Testing for Autonomous Vehicles2023-01-12286/26/2023
Test of autonomous systems is mostly brute force and ad-hoc thus being neither efficient nor transparent. Though requirements invite for a situational transparency, a framework is missing to judge quality of requirements and derived test-cases. Practical challenges are state explosion, difficulty to derive corner cases, no systematic safety of the intended functionality as specified, lack of accepted KPI, etc. Maintaining a valid safety case is hardly possible with such adaptive systems and continuous software updates. To achieve trusted autonomous vehicles, test cases must be generated automatically while at same time providing coverage (e.g., indicating progress with KPI), efficiency (e.g., limiting the amount of regression testing) and transparency (e.g., showing how specific corner cases are tested in case of accidents). This paper provides a method for automatically generating test cases for AI-based autonomous systems and compares it with existing testing methods. A case study is
Ebert, Christof, Weyrich, Michael
Coordinated Electric Vehicle Charging Based on Charging Profile Classification and Power Management Optimizer2023-01-12266/26/2023
The vast increase in electric vehicles (EV) in the market for business and private use implies a necessity to adapt and improve the charging infrastructure. One of the main assets that can be deployed to achieve this goal, is the use of the measured data of the EV supply equipment (EVSE). These data can be implemented to provide a coordinated power management method, which allows coordinated charging according to some predefined criterion and results in a reduced load peak. Analyzing the measured data allows to extract certain features from the charging profile of individual vehicles during the actual charging session. These features represent not only the predefined charging process based on the SOC of the battery but also the behavioral characteristic of the user of the vehicle in terms of its intended use. In this work, a novel approach is introduced, comprising a combined machine learning (ML) classification algorithm and charging power optimizer (CPO). The ML algorithm classifies
Salah, Alia, Abu Mohareb, Omar, Brosi, Frank, Reuss, Hans-Christian
Improving Battery Lifespan and Service Trip Reliability of EVs in Public Transport by Learning Energy Consumption2023-01-12256/26/2023
Electrification of public transport in cities puts lots of stress onto the vehicle's traction batteries and the power grid during charging. A self-learning operating strategy (SELEOS) improves the battery life and reduces stress on the power grid by limiting the charging power as much as feasible and avoiding extreme SoC. During regular service operation, SELEOS observes the vehicle state and energy flows inside of the vehicle and between vehicle and charging infrastructure. Based on these observations, SELEOS plans an optimal SoC trajectory for the trip and dispatches recommendations for charging and discharging the traction battery to the vehicle's ECU. Originating from hybrid buses, SELEOS is designed to work on battery-electric buses (BEB) and battery trolley buses (BTB) as well. In addition to reducing stress to battery and power grid, SELEOS ensures reliable service trips. It does so by checking if the current SoC matches the estimated energy consumption in the near future while
von Kleist, Hermann, Saroch, Lars, Beims, Martin
Analysis of Current Challenges of Automotive Software in the View of Manufacturing2023-01-12216/26/2023
The rapidly growing amount of software in cars reshapes the automotive industry. The software has a significant influence on the production lines, due to the time required to flash it onto the vehicle and its capabilities to test vehicle functions during production. In this paper we identify the main pain points regarding software in the manufacturing process by performing a structured analysis on the experiences made at a major car manufacturer over last two years. In addition, the paper analyses the possible approaches to address the challenges.
Zhai, Yi, Vetter, Andreas, Sax, Eric
User-centred vehicle layout conception for automated vehicles based on digital, human-modelled postures2023-01-12226/26/2023
Autonomous driving is one of the megatrends in the automotive industry. Vehicles that no longer need the driver’s attention raise the expectation among users to use their time gained efficiently. For example automated driving would allow the car to be a place to work, to socialize, to relax or to take a nap. The automated vehicle (AV) would be more of a living space, rather than just a mode of transportation. For the basic vehicle layout new seat configurations, with or without a seat rotation, along with new seating postures must be considered. Until now, the vehicle layout conception is based on a neutral driver posture, this will certainly lead to influences on the vehicle dimensions. Therefore, a geometric analysis with digital human models was conducted with regard to influences of relevant seating parameters on the space needed in a vehicle. We considered new seating postures in use cases linked to automated driving, human anthropometry, seat height (H30), backrest tilt/torso
Fischer, Lutz, Holder, Daniel, Müller, Alexander, Kießling, Jonathan, Gritzbach, Julia, Wirsching, Hans-Joachim, Maier, Thomas
Backend-based State-of-Charge Control as an Operating Strategy for a Serial PHEV2023-01-12016/26/2023
In previous work, a serial hybrid powertrain concept with a phlegmatised ICE has been described. Drivability is to be ensured through an innovative predictive operating strategy. Battery State-of-Charge (SoC) is controlled using a backend-based prediction of energy consumption on a given route based on road map and traffic data. In this paper, a spotlight is thrown on the proposed control architecture. On the top level of the controller, a Dynamic Programming algorithm finds an optimal reference trajectory for the SoC over a known route with the goal of avoiding certain Worst-Case scenarios commonly associated with the serial hybrid powertrain topology. Close adherence to the reference trajectory is ensured on a lower level through Model Predictive Control, taking into account additional factors such as battery stress. These control layers closely represent the map data distributed on the on-board bus network of state-of-the-art road vehicles under the current ADASIS standard. The
Böhme, Maximilian, Gerdts, Matthias, Trapp, Christian
Effects of acoustic dissipative material in applications with acoustic leakage2025-01-01175/5/2023
In the paper, the dissipative material and other conventional acoustic materials are studied in conditions which simulates actual vehicle application with acoustic leakage. The various acoustic materials are evaluated in the lab with acoustic leakage existing in steel panel experimentally and virtually in computer simulation with the estimated Biot’s parameters of the materials. Often, the acoustic leakages exist in actual vehicle condition in pass-through or mounting faster locations. The work includes in-vehicle test results on application and show how the dissipative material works.
Yoo, Taewook, Maeda, Hirotsugu, Sawamoto, Keisuke, Anderson, Brian, Gan, KimTong, Herdtle, Thomas
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