Browse Topic: Iron

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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
Tutorial: Corrosion Phenomena in Brake Systems: From Basics to Future Challenges1334510/11/2022
Corrosion on braking systems is an important issue in the automotive sector. In particular, short term corrosion of the grey cast iron discs can lead to undesired corrosion attack at dealers, while long term corrosion might impair comfort and durability of the braking system. Moreover, corrosion attack of the grey cast iron might cause stiction phenomena between the breaking pad and disc leading to possible damage of the pad. Corrosion phenomena became more important for electrified power train vehicles. In this tutorial, will try to explain the basis of the electrochemical mechanism, some characterization techniques and the interaction on the stiction phenomena between the brake pad sample and the rotor (gray cast iron). Also, another aspect that will be considered is the rust removal conditions and simulations when we are considering Electric Vehicles. The goal is to give to the audience an overview from the basics of the electrochemistry to the experimental conditions test that will
Sin, Agusti
Wear and Friction of PTFE and PEEK Coated Cast Iron Piston Ring 2022-01-03803/29/2022
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.
Comparing and analysing the static and thermal characteristics of brake disc for three different materials2021-28-025310/1/2021
In automobiles, the most commonly used braking system is disc brake. In the brake disc, rotor is the rotating part of a wheel's disc brake assembly, against which the brake pads are applied by the driver through mechanical action. So, the disk is the important component in either slowing down or stopping the vehicle. These discs were commonly made of cast iron conventionally. But the limitations with respect to cast iron are that they have less corrosion resistance and heavy in weight. In order to overcome the above-said complications, alternate materials for disc have to be found. The main objective of this paper is to analyze the characteristics of three different materials and compare their results and suggest a suitable material that highly influences the conventional material and has better performance under on-road rigorous braking conditions. In order to find an alternative material for Cast Iron (CI), EN31, Ti-6Al-4V(Ti alloy) acts as a potential candidate in offering great
K, Kaviyarasan, R, Soundararajan, Richter R, Abhisheak, K, Siva, Purusothaman, S, S, Shiva Gurunathan
A Holistic Approach of Developing New High Strength Cast Iron for Weight Optimization2021-26-02449/22/2021
Cast Iron is being used in various Industries like Automotive, Agriculture, Construction etc., for many decades. Metal casting processes have its unique advantages like ease of heavy weight castings, intricate shapes, higher productivity. Commercially viable (low cost) etc., using wide range of materials like Gray cast iron, Spheroidal cast iron, Malleable cast iron ,cast steel etc., Cast iron have an excellent properties like high dampening capacity, higher thermal conductivity, wear resistance required by many critical applications. These unique combinations will be chosen to serve the purposes both functionally and commercially. However, in last one-decade automotive and agriculture industries are facing issue of fuel economy which directly influenced by the weight of the vehicle. For off-road vehicle like tractors, One of the major contributor in vehicle weight is cast iron. Many material grades and strengthening mechanisms are recently being evolved to optimize the cast iron
Gunalan, Magendran, Anandeswaran, V.A
Tiny, Magnetically Powered Neural StimulatorTBMG-3800811/1/2020
Neuroengineers have created a tiny surgical implant that can electrically stimulate the brain and nervous system without using a battery or wired power supply. The device draws its power from magnetic energy and is about the size of a grain of rice. It is the first magnetically powered neural stimulator that produces the same kind of high-frequency signals as clinically approved, battery-powered implants that are used to treat epilepsy, Parkinson’s disease, chronic pain, and other conditions.
Rust Is Not a Must. Improvement of Discs Corrosion Resistance by Tuning of Grey Cast Iron Alloying Elements and Microstructure2020-01-162410/5/2020
The manuscript reports about the corrosion performance of a series of grey cast iron specimens including an increasing concentration of Aluminum as alloying element. An improved corrosion resistance for %Al >1%wt is demonstrated and a reasonable corrosion mechanism is proposed as well. Electrochemical techniques allow to calculate a particularly high corrosion potential (Ecorr) for the sample including 4%wt Al, equals to -572 mV vs. Saturated Calomel Electrode (SCE). The manuscript is aimed at demonstrating that the fine tuning of alloying elements in cast iron is a particularly effective method in order to improve its corrosion resistance, thus allowing the development of future disc-brake rotors with a prolonged operating life.
Bertasi, Federico, Dudzik, Bozena, Mancini, Alessandro, Bandiera, Marco, Biondo, Simone, Bonfanti, Andrea
Wear Performances of Gray Cast Iron Brake Rotor with Plasma Electrolytic Aluminating Coating against Different Pads2020-01-162310/5/2020
Gray cast iron brake rotor experiences substantial wear during braking and contributes largely to the wear debris emissions. Surface coating on the gray cast iron rotor represents a trending approach dealing with the problems. In this research, a new plasma electrolytic aluminating (PEA) process was used for preparing an alumina-based ceramic coating with metallurgical bonding to the gray cast iron. Three different types of brake pads (ceramic, semi-metallic and non asbestos organic (NAO)) were used for tribotests. Performances of PEA coatings vs. different brake pad materials were comparatively investigated with respect to their coefficients of friction (COFs) and wear. The PEA-coated brake rotor has a dimple-like surface which promotes the formation of a thin transferred film to protect the rotor from wear. The transferred film materials come from the wear debris of the pads. The secondary plateaus are regenerated on the brake pads through compacting wear debris of the pads. The wear
Cai, Ran, Zhang, Jingzeng, Tjong, Jimi, Nie, Xueyuan
Fabrication of Multilayer Ferritin ArraysTBMG-371967/1/2020
NASA Langley Research Center has developed a method of depositing arrays of a ferritin protein on a substrate to create a thin-film electrode for a bio-nanobattery. The method is a spin self-assembly procedure by which a first ferritin layer is formed on the substrate, followed by building a second oppositely charged ferritin layer on the top of the first to form a bilayer structure. Oppositely charged ferritin layers are subsequently deposited on top of each other until a desired number of bilayer structures is produced. The result is an ordered, uniform, stable, and robust thin-film electrode material of enhanced packing density that provides optimal charge density for the bio-nanobattery.
Design Consideration for Lightweighting With Ductile Iron Castings2020-01-06564/14/2020
There are opportunities for lightweighting with ductile iron castings. Current research shows ductile iron castings free of massive carbides can be achieved at under 2 mm (0.080”) through alloying or process changes which means that significant weight reductions are possible. In fact for aluminum components over 0.250” thick ductile iron may provide lightweighting opportunities at a cost savings. However, the conventional guidelines for casting design are inadequate when using ductile iron at dimensions less than the typical machine stock. This paper will discuss the current research on thin walled ductile iron, when it is superior to aluminum, design considerations, and current DOE SBIR funded research efforts to address these inadequacies.
Jordan, Sarah, DeBruin, Mark, Brown, Christopher, Gasvoda, Hudson
Microstructure-Fatigue Property Relationships for Cast Irons2020-01-01874/14/2020
Cast irons are widely used for combustion engine/exhaust system applications, not only because they are less expensive but also because they offer some attractive properties such as good thermal conductivity, relatively high specific yield strength, and good oxidation resistance. Cast irons can be made with a wide variety of microstructures containing either flake-like graphite (FG), nodular graphite (NG) or vermicular graphite (VG), or mixing of the above, which control their mechanical and fatigue properties. In this paper, a microstructure-fatigue property relationship model is developed, combining the Tanaka-Mura-Wu’s fatigue crack nucleation model with Eshelby’s solution for materials containing ellipsoidal inclusions. This applies to cast irons considering its microstructural graphite characters (shape, size, elastic modulus and Poisson’s ratio). This model is used to analyse ductile cast iron (DCI) with nodular graphite (NG) microstructure, grey cast iron (GCI) with flake-like
Wu, Xijia
Secure Optical Mobile Local Communications Systems Support Royal NavyTBMG-366114/1/2020
Link Microtek Hampshire, UK +44 (0)1256 355771
Advances in Drilling with PCD (Polycrystalline Diamond)2020-01-00353/10/2020
PCD properties were optimized to drill stacks of CFRP/Ti using an accelerated wear test milling gray cast iron. The optimized PCD was then used to prepare PCD drills. Tests were made to determine the best drilling conditions for the optimized PCD. The results yielded a significant improvement in cycle times as compared to earlier studies using PCD drills. Notched PCD cutting edges were found to eliminate oversizing of the CFRP near the interface of the two materials.
Bunting, Jeremy, Bunting, John
Advances in Drilling with PCD (Polycrystalline Diamond)2020-01-00353/10/2020
PCD properties were optimized to drill stacks of CFRP/Ti using an accelerated wear test milling gray cast iron. The optimized PCD was then used to prepare PCD drills. Tests were made to determine the best drilling conditions for the optimized PCD. The results yielded a significant improvement in cycle times as compared to earlier studies using PCD drills. Notched PCD cutting edges were found to eliminate oversizing of the CFRP near the interface of the two materials.
Bunting, Jeremy, Bunting, John
Iron Nanorobots Destroy Cancer CellsTBMG-362383/1/2020
Drug-coated iron nanowires that can be guided to the site of a tumor using an external magnetic field before activating a three-step cancer-killing mechanism could provide an effective option for cancer therapy.
Design Treatment for Advanced Metals Enables Easier MachiningTBMG-358021/1/2020
Exotic and advanced metals are used in aircraft, orthopedic components, medical instruments, cars, solar panels, military equipment, and other applications. They are referred to as advanced or exotic because they are more difficult to find and more costly to use in manufacturing.
Ultra-Thin Layers of Rust Generate Electricity from Flowing WaterTBMG-3572212/1/2019
Research shows that thin films of rust (iron oxide) can generate electricity when saltwater flows over them. These films represent an entirely new way of generating electricity and could be used to develop new forms of sustainable power production.
Brake Rotor Corrosion and Friction Cleaning Effect on Vehicle Judder Performance2019-01-21159/15/2019
Brake disc corrosion has emerged as an important field of study within the automotive industry due to the wide range of lining materials that are currently used worldwide, and their inherent rust-cleaning properties. The presence of oxide layers irregularly deposited on the cast iron disc surfaces usually leads to a forced, braking-induced vibration that can reach the driver’s position as a pronounced annoyance. Hence, the friction material composition directly impacts on the judder performance during the early corrosion-removal stage. This study incorporates both dynamometer and vehicle tests into the definition of a predictive methodology that allows corrosion-induced vibrations to be investigated at both system and vehicle levels. The oxide film is artificially generated by means of a salt spray chamber under steady-state climate conditions in order to guarantee a repetitive and robust procedure. The vibration response of the system is objectively evaluated in the form of caliper
Molina Montasell, Narcís, Ferrer, Bernat
Ceramic Bound Materials: A Suitable Solution for Light Brakes2019-01-21099/15/2019
A ceramic bound matrix has been investigated to be used as a friction material. The materials were produced by means of ceramic technology using frits containing silicates, and ceramic friction modifiers such as tin oxide, zircon, iron oxide, magnesium oxide. Four formulations were tested by means of a tribometer (pin-on-disc tester) using a gray cast iron counterpart. Test section included speeds between 1 and 12 ms-1, and loads between 25 and 400 N. The coefficient of friction of the tested specimens were between 0.7 and 0.4, and exhibited sensitivity to speed at low loads (25 N), while they are quite stables at high loads (400N). The characterization of the tribolayers was carried out by means of scanning electron microscopy. The four developed materials were named A, B, C, and D. They exhibited different wear rates and coefficients of friction. All the materials exhibited sensitivity to speed, while showed a lower sensitivity to load. The coefficient of friction level seems to be
Dante, Roberto C., Cotilli, Edoardo, Conforti, Michael, Cotilli, Mario, Serrano-Posada, José Carlos, Schramm, Tobias, Ostermeyer, Georg-Peter, Dastrù, Marco
3D-Printed Soft Mesh RobotsTBMG-351559/1/2019
Researchers have created 3D-printed flexible mesh structures that can be controlled with applied magnetic fields while floating on water. The structures can grab small objects and carry water droplets, giving them the potential to be useful as soft robots that mimic creatures living on water surfaces or that can serve as tissue scaffolds for cell cultures.
Optimized Requirements Verification for Flexible Drive ShaftsF-0075-2019-145455/13/2019
An optimized design, fabrication and testing solution is presented for flexible drive systems. A single piece welded drive shaft as well as a system consisting of sub and supercritical shafts, couplings and bearing hangers (for Tail Drive System in Helicopters and Interconnect Drive Systems in Tiltrotors) are included. This solution facilitates the qualification for flight of the drive shaft in airframes with reduced iron bird and expensive flight testing on the airframe. This solution also provides opportunities for improvements during the prototype phase such that potential deficiencies are identified and corrected before the drive shaft is put into service. An important part of the testing is accelerated testing, not in terms of operational life, but in terms of reliability. Theoretical Life of a flexible drive shaft is 'infinite' by design. 2.0
King, Michael, Schaefer, Joyel, Iyer, Raghu
Iron-Nickel Alloy Strip 49Fe - 5.3Cr - 42Ni - 2.5Ti - 0.55Al Solution Heat TreatedAMS5221F (Historical)1/10/2019
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
Iron-Nickel Alloy Strip 49Fe - 5.3Cr - 42Ni - 2.5Ti - 0.55Al Solution Heat TreatedAMS5221F-TEST-REC (Historical)1/10/2019
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
Physical and Virtual Simulation of Lightweight Brake Drum Design for Heavy Duty Commercial Vehicles Using Alternate Material Technologies2018-01-189710/5/2018
Brake drum in commercial vehicles is very important aggregate contributing towards major weight in brake system module. The main function of brake drum is to dissipate kinetic energy of vehicle into thermal energy, as a results in braking operation major load comes on brake drum. Hence this is very critical component for vehicle safety and stability [1]. Objective of this paper is to increase the pay load, which is utmost important parameter for commercial vehicle end customers. To achieve the light weighing target, alternate materials such as Spheroidal graphite iron (SGI) has been evaluated for development of brake drum. Many critical parameters in terms of reliability, safety and durability, thickness of hub, wheel loading, heat generation on drum, manufacturing and assembly process are taken into consideration. The sensitivity of these parameters is studied for optimum design, could be chosen complying each other’s values. Digital thermal performance evaluated in house, fine-tuned
Kandreegula, Suresh Kumar, Deshmukh, Himanshu, Prasad, Shivdayal, Paroche, Sonu, Anil Shah, Ashesh
The Factors Governing Corrosion Stiction of Brake Friction Materials to a Gray Cast Iron Disc2018-01-189910/5/2018
Corrosion stiction at the contact interface between a brake friction material and a gray iron disc under the parking brake condition was investigated by evaluating the possible parameters that affect the shear force to detach the corroded interface. Using production brake friction materials, comprising non-steel and low-steel types, corrosion tests were carried out by pressing the brake pad onto the gray iron disc using a clamp at various conditions. Results showed that the shear force to detach the corroded interface tended to increase with applied pressure and corrosion time. On the other hand, porosity, acidity, and hydrophobicity of the friction material did not show a reliable correlation to the stiction force. The poor correlation of the stiction force with the friction material properties indicated that the stiction force was not determined by a single factor but governed by multiple parameters including surface contact areas and inhomogeneity of the ingredients. Microscopic
Gweon, Jaehyun, Shin, Sanghee, Jang, Ho, Lee, Wangyu, Kim, Dooyeon, Lee, Keeyang
A Study of the Disc Scoring Generation Principle and Reduction (II)2018-01-189110/5/2018
In the latest paper [10], we presented our work based on experiments studying MPU (Metal Pick Up) of the pad and scoring(scratching) of the disc. The main component of MPU was iron “Fe”. If the roughness of the disc was small, the content of iron “Fe” was increased and the segregation of that was decreased especially in initial condition. In this study, we extended our study based on the results by adding some additional factors such as the location of the roughness of the disc, the coefficients brake pad friction, and disc slots. We made various discs of different roughness boundaries and slots, and pads of pad friction coefficients; and conducted two types of tests for whether a slot is present or not with the other same conditions to confirm the impact of the scoring. We find and believe that our experimental data should serve a useful guideline for reducing MPU of the pad and scoring of the disc.
Jeong, ByeongUk, Ryu, Hyoung Tae, Kim, Chang Jin, Jung, Kwang Ki, Lee, Hyunkyoung
Iron-Nickel Alloy, Bars, Forgings, and Rings 42Fe - 37.5Ni - 14Co - 4.8 (Cb + Ta)(Nb + Ta) - 1.6Ti Solution Heat Treated, Short-Time Precipitation Hardenable Multiple Melted, High Temperature, Low ExpansionAMS5893C (Historical)8/16/2018
This specification covers an iron-nickel alloy in the form of bars, forgings, flash-welded rings, and stock for forging, flash-welded rings, or heading.
AMS F Corrosion Heat Resistant Alloys Committee
Iron-Nickel Alloy, Bars, Forgings, and Rings 42Fe - 37.5Ni - 14Co - 4.8 (Cb + Ta)(Nb + Ta) - 1.6Ti Solution Heat Treated, Short-Time Precipitation Hardenable Multiple Melted, High Temperature, Low ExpansionAMS5893C-TEST-REC (Historical)8/16/2018
This specification covers an iron-nickel alloy in the form of bars, forgings, flash-welded rings, and stock for forging, flash-welded rings, or heading.
AMS F Corrosion Heat Resistant Alloys Committee
Multi-Attribute, System-Level Design Process for Automotive Powertrain Electric Drives: An Integrated Approach08-07-02-00076/5/2018
This article presents an electric drive powertrain design and virtual integration methodology in the context of electric vehicle systems. In the first stage, using the Model-Based System Engineering paradigm, the electric vehicle performance requirements are translated into electric drive target specifications using a system-level vehicle model. Subsequently, a functional electric drive subsystem-level model is developed based on magnetic co-energy and iron losses data obtained from a reference electric machine design. The functional electric drive model is scaled in order to meet the requested specifications, and it is coupled with different 1D (i.e. lumped-parameter) multi-physics sub-models that are later integrated into the electric vehicle system-level model. At the electric drive level the torque ripple and Noise, Vibration and Harshness characteristics are analyzed. At the vehicle level the energy consumption, thermal behavior, and mechanical performances are determined with
Ciceo, Sebastian, Faria, Cassio T., Gyselinck, Johan, Martis, Claudia
Response of Austempering Heat Treatment on Microstructure and Mechanical Property in Different Zones of As-Welded Ductile Iron (DI)05-11-02-00165/8/2018
Sound ductile iron (DI) welded joints were performed using developed coated electrode and optimized welding parameters including post weld heat treatment (PWHT). Weldments consisting of weld metal, partially melted zone (PMZ), heat affected zone (HAZ) and base metal were austenitized at 900 °C for 2 hour and austempered at 300 °C and 350 °C for three different holding time (1.5 hour, 2 hour and 2.5 hour). In as-weld condition, microstructures of weld metal and PMZ show ledeburitic carbide and alloyed pearlite, but differ with their amount. Whereas microstructure of HAZ shows pearlite with some ledeburitic carbide and base metal shows only ferrite. However, in spite of the significant variation in microstructures at different zones of weldment in as-weld condition, all the zones show similar microstructure of base metal such as bainitic ferrite along with some retained austenite after austempering heat treatment, indicating the response of heat treatment from different zones like base
Sarkar, Tapan, Pal, Tapan Kumar
Modelling of Electrode Erosion for Prediction of Spark Plug Lifetime2018-01-01754/3/2018
A high-fidelity arc plasma simulation tool has been developed that can model arc physics coupled with electrode erosion. The arc physics is modelled using an equilibrium, resistive magneto-hydrodynamic (MHD) model. Solid electrodes are modelled using an immersed boundary method that allows for the electrodes to deform dynamically without modifying the original mesh or the underlying governing equations. First, a partial validation of the arc physics is performed by comparing arc stretch in cross-flow with experimental results across a 1.1 mm spark gap. Subsequently, the ability to model arc physics in a coupled manner with ablating electrodes is demonstrated in 2D using a 0.7 mm electrode gap with iron electrodes. The objective of this work is to illustrate modeling of coupled arc physics with eroding electrodes; a capability that will be extended for the realistic prediction of spark plug lifetimes in future work.
Breden, Douglas P., Karpatne, Anand, Raja, Laxminarayan
An Integrated Approach to Constitutive Modeling and Life Prediction for Automotive Materials2018-01-12134/3/2018
An integrated approach of constitutive modeling and life prediction is presented through introduction of the integrated creep-fatigue theory (ICFT). The ICFT is formulated based on participating deformation and damage mechanisms, which not only describes the cyclic deformation behavior but also the life and fracture mode. Automotive exhaust system materials such as ductile cast iron and austenitic cast steel are used as example materials for demonstration in good agreement with experimental results and metallurgical examinations. This enlightens the understanding of the roles each mechanism plays in low-cycle fatigue (LCF) and thermomechanical (TMF) processes, thus helping material and component design specifically targeting the most damaging mechanism(s) encountered in service.
Wu, Xijia
Automotive Compacted Graphite Iron CastingsJ1887_201802 (Current)2/15/2018
This SAE Standard covers the mechanical and physical requirements for Compacted Graphite Iron (CGI) castings used in automotive and allied industries. Requirements in this document include: a Tensile Strength b Yield Strength c Elongation d Graphite Morphology
Metals Technical Committee
Tech Briefs April 201818AERP022/1/2018
Multi-Domain Command and Control (MDC2) Changing the Face of Modern Warfare Loop Thermosyphons Gravity-Driven Two-Phase Cooling for the 21st Century CompactPCI Serial Space A New Embedded System Specification Takes on Extreme Environments Plain Bearings for Aerospace Applications Additive Manufacturing Materials for RF Components NASA CubeSats: Pushing the Boundaries of Technology Content Addressable Memory (CAM) Technologies for Big Data and Intelligent Electronics Enabled By Magneto-Electric Ternary CAM New associative memory approach based on the propagation of spikes provides ultra-low energy search operations. Natural DNA-Based Nonvolatile Resistive Switching Memory Reliable memory devices can be realized within a single macromolecule based on natural DNA. A Mechanistic Analysis of Oxygen Vacancy Driven Conductive Filament Formation in Resistive Random Access Memory Metal/NiO/Metal Structures Study could lead to more efficient electrically switchable resistive random access memory
Elevated Temperature Properties of Cast IronsJ125_201801 (Current)1/9/2018
The purpose of this SAE Information Report is to provide automotive engineers and designers with a concise statement of the basic characteristics of cast iron under elevated temperature conditions. As such, the report concentrates on general statements regarding these properties with limited illustrative data, anticipating that those who may be interested in more detail will want to use the bibliography provided at the conclusion of the report.
Metals Technical Committee
Elevated Temperature Properties of Cast IronsJ125_201801-TEST-REC (Historical)1/9/2018
The purpose of this SAE Information Report is to provide automotive engineers and designers with a concise statement of the basic characteristics of cast iron under elevated temperature conditions. As such, the report concentrates on general statements regarding these properties with limited illustrative data, anticipating that those who may be interested in more detail will want to use the bibliography provided at the conclusion of the report.
Metals Technical Committee
Controlling Soft Robots Using Magnetic FieldsTBMG-281911/1/2018
A fundamental advance in controlling soft robots involves using magnetic fields to remotely manipulate microparticle chains embedded in soft robotic devices. Several devices have been developed that make use of the new technique. Possible applications for these devices range from remotely triggered pumps for drug delivery, to the development of remotely deployable structures.
Using Sunlight to Activate the Flow of Electrical Current in a New MaterialTBMG-275369/1/2017
Mined to make the first compass needles, the mineral magnetite is also made by migratory birds and other animals to allow them to sense north and south, and thus navigate in cloudy or dark atmospheric conditions or under water. Researchers have compositionally modified magnetite to capture visible sunlight and convert this light energy into electrical current. This current may be useful to drive the decomposition of water into hydrogen and oxygen. The team generated this material by replacing one third of the iron atoms with chromium atoms.
Omnidirectional Mobile Robot with Two Moving PartsTBMG-270356/1/2017
SIMbot is an updated version of the ballbot, an elegantly simple robot whose tall, thin body moves on top of a sphere slightly smaller than a bowling ball. SIMbot features a motor with just one moving part: the ball. The other active moving part of the robot is the body itself.
Corrosion-Resistant Steel Parts: Sampling, Inspection and Testing for Surface PassivationAMSSTD753B (Current)4/4/2017
This standard describes general and detailed methods of sampling and testing for surface passivity of corrosion-resistant steel parts. These tests may also be useful to determine if there is a need for passivation.
AMS F Corrosion Heat Resistant Alloys Committee
Corrosion-Resistant Steel Parts: Sampling, Inspection and Testing for Surface PassivationAMSSTD753B-TEST-REC (Historical)4/4/2017
This standard describes general and detailed methods of sampling and testing for surface passivity of corrosion-resistant steel parts. These tests may also be useful to determine if there is a need for passivation.
AMS F Corrosion Heat Resistant Alloys Committee
Development of High Efficiency Rectifier with MOSFET in “eSC Alternator”2017-01-12283/28/2017
Alternator, which supplies electric energy to a battery and electrical loads when it is rotated by engine via belt, is one of key components to improve vehicle fuel efficiency. We have reduced rectification loss from AC to DC with a MOSFET instead of a rectifier diode. It is important to turn on the MOSFET and off during a rectification period, called synchronous control, to avoid a current flow in the reverse direction from the battery. We turn it off so as to remain a certain conduction period through a body diode of the MOSFET before the rectification end. It is controlled by making a feedback process to coincide with an internal target conduction period based on the rotational speed of the alternator. We reduced a voltage surge risk at turn-off by changing the feedback gain depending on the sign of the time difference between the measured period and the target. In addition to reducing the rectification loss, reducing copper loss with low resistance coil winding and iron loss with
Nakanishi, Masaya
The Development of Direct Drive Motors for Solar Cars2017-01-12323/28/2017
Solar car races are held worldwide, aiming to promote vehicles that help reduce environmental loads on the roads. In order to gain superiority in solar car racing, it is essential to develop a high efficiency brushless direct drive motor that optimizes the energy use to the fullest and allows high speed driving when needed. To achieve these goals, two development approaches of solar car motors are proposed: the high efficiency motor which improves electrical characteristics and significantly reduces energy loss; and the variable field magnet motor that offers instant speed boost for a temporary period of time for overtaking opponents. We have developed a high efficiency motor through the application of an amorphous core and laminated magnets. Instead of the standard method of the W-EDM (Wire-Electric Discharge Machining) for amorphous cores, we utilized water jet cutting, through which we succeeded in achieving insulation between laminated cores. In general, a sheet of magnet is used
Yamazakii, Tsubasa, Uchiyama, Hidekazu, Nakazawa, Kazuaki, Isomura, Tsubasa, Ogata, Hisashi
Lifetime Assessment of Cylinder Heads for Efficient Heavy Duty Engines Part I: A Discussion on Thermomechanical and High-Cycle Fatigue as Well as Thermophysical Properties of Lamellar Graphite Cast Iron GJL250 and Vermicular Graphite Cast Iron GJV4502017-01-03493/28/2017
Cast iron materials are used as materials for cylinder heads for heavy duty internal combustion engines. These components must withstand severe cyclic mechanical and thermal loads throughout their service life. While high-cycle fatigue (HCF) is dominant for the material in the water jacket region, the combination of thermal transients with mechanical load cycles results in thermomechanical fatigue (TMF) of the material in the fire deck region, even including superimposed TMF and HCF loads. Increasing the efficiency of the engines directly leads to increasing combustion pressure and temperature and, thus, lower safety margins for the currently used cast iron materials or alternatively the need for superior cast iron materials. In this paper (Part I), the TMF properties of the lamellar graphite cast iron GJL250 and the vermicular graphite cast iron GJV450 are characterized in uniaxial tests and a mechanism-based model for TMF life prediction is developed for both materials. The model can
Seifert, Thomas, von Hartrott, Philipp, Boss, Kristopher, Wynthein, Paul
Fatigue Assessment of Nodular Cast Iron with Material Imperfections2017-01-03443/28/2017
For the design of thick-walled nodular cast iron components, fatigue assessment, especially in the context of local imperfections in the material, is a challenging task. Not only the cyclic material behavior of the sound baseline material, but also the cyclic behavior of materials with imperfections, such as shrinkages, dross and chunky graphite, needs to be considered during the design process of cast iron components. In addition to this, new materials, such as solid solution strengthened alloys, offer new possibilities in lightweight design, but need to be assessed concerning their fatigue strength and elastic-plastic material behavior. If a safe and reproducible fatigue assessment for any component cannot be performed and a secure usage is therefore not given, the cast components are generally rejected, leading to a loss of additional material, energy and money for recasting the component. In this context, four nodular cast iron materials are compared with reference to their cyclic
Bleicher, Christoph, wagener, Rainer, Kaufmann, Heinz, Melz, Tobias
Lifetime Assessment of Cylinder Heads for Efficient Heavy Duty Engines Part II: Component-Level Application of Advanced Models for Thermomechanical Fatigue Life Prediction of Lamellar Graphite Cast Iron GJL250 and Vermicular Graphite Cast Iron GJV450 Cylinder Heads2017-01-03463/28/2017
A complete thermomechanical fatigue (TMF) life prediction methodology is developed for predicting the TMF life of cast iron cylinder heads for efficient heavy duty internal combustion engines. The methodology uses transient temperature fields as thermal loads for the non-linear structural finite-element analysis (FEA). To obtain reliable stress and strain histories in the FEA for cast iron materials, a time and temperature dependent plasticity model which accounts for viscous effects, non-linear kinematic hardening and tension-compression asymmetry is required. For this purpose a unified elasto-viscoplastic Chaboche model coupled with damage is developed and implemented as a user material model (USERMAT) in the general purpose FEA program ANSYS. In addition, the mechanism-based DTMF model for TMF life prediction developed in Part I of the paper is extended to three-dimensional stress states under transient non-proportional loading conditions. The material properties of the plasticity
Hazime, Radwan, Seifert, Thomas, Kessens, Jeremy, Ju, Frank
Linear Actuators for High-Speed, Low-Load ApplicationsTBMG-262361/1/2017
A number of medical applications need high-speed actuation in the lower load band. Many OEMs use pneumatic actuators or electric solenoids for this purpose; however, these options do not provide precise positioning. And, although more expensive technology such as servo pneumatic positioning systems are available, accurate positioning at high speeds is still difficult with pneumatic systems.
Fine-Tuning of Rotor Gray Iron Material for Optimal Brake Performance2016-01-19429/18/2016
Developing a brake system with high overall customer satisfaction rating is a constant challenge for OEMs as well as their brake suppliers. Brake system performance is directly linked to the engagement between the rotors and pads. The materials for the rotors and pads play a key role in the nature of the engagement. Therefore, to meet the performance targets, it is critical to have a good understanding of the brake rotor materials and their impacts. Gray iron is the most widely used brake rotor material in the industry owing to its superior thermal handling capacity, damping characteristics, and wear and cost advantages. G30 per ASTM A48 is generally specified for most brake rotors with minimum tensile strength of 200 MPa and Brinell hardness of 187∼241. G20 is also widely used for brake rotors, especially for brake smoothness and optimal lining life. This study has found that variations in gray iron material can considerably affect brake fiction coupling behaviors and hence the
Chen, Sarah, Hoxie, Steve
Development of Aluminum Composite Automotive Brake Rotors2016-01-19379/18/2016
Aluminum metal matrix composite brake rotors with a selective ceramic function reinforcement gradient (FRG) have been developed for automotive applications. This paper will highlight the design, manufacturing, and testing of the rotors. Weight saving of an aluminum composite rotor in comparison to an industry standard cast iron rotor is 50-60%. With this material change comes design considerations to manage rotor temperature, rotor surface integrity, and friction. Manufacturing methods to meet these design constraints were needed to develop a viable high performance aluminum composite rotor. High pressure squeeze casting with soluble coring techniques were developed to incorporate the selective FRG MMC rotors. Dynamometer testing was performed, concentrating on brake friction and temperature to evaluate the macro and micro interfaces in the rotors. The rotors’ testing results indicate that a functional reinforced aluminum metal matrix composite rotor is viable option for front and rear
Erva, Taylor, Loukus, Adam, Luskin, Luke
A Novel Equivalent Circuit Model for Lithium-ion Battery with Complex Electrical Element Parameters2016-01-11974/5/2016
An equivalent circuit model for lithium-ion battery including capacitor and inductor with complex parameters is proposed. The imaginary part of the complex-valued capacitor expresses diffusion processes instead of constant phase element, which leads to a higher computational efficiency by removing the exponential variant calculation. The inductor with the complex parameter, the imaginary part accounting for the frequency-dependent magnetic hysteresis loss of battery current collectors and cables, can accurately regenerate the impedance characteristics at high frequencies with various linear slope angles to the real axis in a Nyquist plot. The fitted electrochemical impedance spectrum of a lithium iron phosphate/graphite battery with this proposed model is compared to the measured data. The maximum relative error of the impedance magnitude is 4.94% at the frequencies between 0.01 Hz and 10 kHz. The electrical component parameters of the proposed equivalent circuit model are calculated
Wu, Zhengbin, Weng, Rongcheng, Zhang, Zhiqun, Li, Juan
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