This procedure is intended to apply to fuel pumps. This procedure will be defined in terms of recommended test fluid, test setup, test conditions, and test method. This procedure may be used for other fuel system components, by testing in conjunction with the pump, which normally supplies the component inlet flow, or a substitute test pump of similar capacity. This procedure may be used, with variations in test conditions and test fluid for performing pump evaluation tests. Tests at progressively increasing pump speeds and pressures will provide design limitation data. Alternate test periods on a test pump and another pump, of a design for which actual service durability is known, will provide useful comparison data.

AE-5B Aircraft and Engine Fuel and Lubricant Sys Components

1D Thermo-Fluid Model for Electric Vehicle Traction Inverter

2025-01-50629/19/2025

Thermal management solutions in power electronics applications are of prime importance to meet the needs of the ever-increasing demands on higher power and torque density of the traction motor and controller. Traction inverters are essential power electronic devices that convert direct current (DC) supply from the battery pack of the vehicle to three-phase alternating current (AC) output and vice versa. Estimation of die junction temperatures and cooling system pressure drop is necessary for assessing the maximum heat load capacity of the traction inverter system and coolant pump capacity requirements. The system comprises of a power module and a water–glycol–based cooling domain with heat sink. This article proposes a 1D model for accurate predictions of junction temperatures on the SiC die, temperature rise of the cooling medium, and pressure drop across a custom heat sink fluid domain. The model is built to handle steady-state and transient conditions for varying heat loads on the

Ravindra, Vidyasagar, Prasad, Praveen, Singh, Ishan, Sureka, Sumit

Multi-Physics Modeling and Planning Tool for Tailoring of Quenching Process of Representative Airframe Structural Components

F-0081-2025-0389

5/20/2025

Quenching is the most critical step in the sequence of heat-treating operations, aiming to preserve the solid solution formed at the solution heat-treating temperature by rapidly cooling the material to near room temperature. Currently, there is no reliable, performance-informed quenching process that can consistently reduce the high scrap rate of airframe aluminum forging parts, which often suffer from significant residual stress and distortion. This limitation stems from the complex interactions between temperature, phase transformations, and stress/strain behavior—each influenced by the evolving temperature distribution and microstructural state of the workpiece. Conventional modeling techniques for quenching processes typically lump these multiscale, multi-physics phenomena into a simplified heat transfer coefficient (HTC). However, determining the spatial and temporal variations of HTC through experiments is both prohibitively time-consuming and costly. To address this challenge

Lua, Jim, Shrestha, Kalyan, Karuppiah, Anand, Timko, Mark, Lund, Scot, Li, Rui

Multi-Physics Informed Planning for Hybrid Metal Additive and Subtractive Manufacturing

F-0081-2025-0355

5/20/2025

Hybrid additive manufacturing (AM) and subtractive manufacturing (SM) processes utilize the combination of AM (e.g., LPBF and DED) and SM (e.g., milling and turning operations) to produce the final part. Due to the poor surface roughness resulting from the uneven melting of powders in AM, the subtractive process is a necessary finishing operation to improve the surface roughness of the AM part. The hybrid AM/SM technology combines the benefits of AM and SM processes to create complex geometry while introducing good surface finish and compressive stress to prevent crack initiation. However, the relationship between large process parameter space and the residual stress/distortion in the part is not well understood, which impedes the adoption of hybrid AM/SM to minimize the residual stress in the final product. To expedite the process optimization, we establish a pipeline for the sequential modeling of additive manufacturing (AM) and subtractive manufacturing (SM) processes. Key

Lua, Jim, Li, Rui, Rajanna, Manoj, Haridas, Ravi Sankar, Mishra, Rajiv

Analysis of Complex Transmission Systems, Leveraging SPH Analysis and Reduced Order Modeling

F-0081-2025-0262

5/20/2025

There is a continued and growing need for better analysis and simulation of complex transmission systems with the rise of hybrid electric powerplants coming to future aviation vehicles. In this paper we discuss how reduced order modeling can help to efficiently predict the thermal behavior of gearboxes during operations smartly reusing data from SPH based oil flow simulations. To solve the thermal problem, a dynamic non-linear Reduced Order Model (ROM) is generated to estimate the Gear-Oil heat transfer coefficient (HTC) based on variable gearbox RPM and Oil fill level.

Mallios, Spyridon, Cole, Blaise

EDITORIAL: Farewell and thanks, Mr. Birch

21AUTP06_041/27/2025

“We pay close attention to the SAE magazines because your guy in Europe writes interesting articles,” a BMW engineering executive told me one year at the Frankfurt Motor Show. He was referring to Stuart Birch, our veteran European Editor, who has recently decided - after nearly 37 years of outstanding reporting for SAE International - to hang up his keyboard and spend more time with his wife, Kim, their family and friends in the British countryside, and his classic Porsche 911. Our staff had been dreading the day that Stuart would announce his retirement, foremost because he's been a great friend as well as a colleague. And because journalists with his qualities - professionalism, perspective, a powerful work ethic and great wit - are increasingly rare in the mobility-technology space. As SAE's global audience knew, Stuart Birch delivered compelling technical and business information. He covered product, processes and people with equal poise. And he thrived on the R&D beat: Virtual

Brooke, Lindsay

Performance Analysis of Graphene-Coated Heat Pipe Heat Exchangers for Automobile Exhaust Cooling and Purification

2025-01-50061/23/2025

This research investigates the development of a heat pipe heat exchanger coated with graphene for cooling and purification of automobile exhausts. The heat exchanger directly affects the performance of the engine because proper heat dissipation and transfer can improve engine performance, reduce fuel consumption, and decrease the emission. Moreover, this effect is much more noticeable on coated heat pipes because of the enhanced thermal conductivity and mechanical properties of the graphene films. A heat null emitted by internal combustion engines was used in the experimental setup to test the thermal performance, cooling efficiency, and purification efficiency of the newly designed in-house exhaust simulation system where the new heat pipes were inserted. The results of the experiment show that the heat pipes have very high thermal performance as the efficiency of the heat pipes was calculated to be around 85%. Furthermore, the temperature decrease over the surfaces of the heat

Karthigairajan, M., Seeniappan, Kaliappan, Balaji, N., Natrayan, L., Sheik, Salman Basha, Ravi, D.

Analyses of Cold Thermal Energy Storage Systems Using Eutectic Mixtures of Inorganic Hydrated Salts as Phase Change Materials

2025-01-50031/23/2025

Cold thermal energy storage using phase changing materials is being researched to find freezing and thawing points. The use of inorganic hydrated salts, a type of phase changing material (PCM) used in cold energy storage systems without the use of existing renewable energy systems, allows for a longer cooling effect and saves energy. A high volumetric storage density and relatively high thermal conductivity make hydrated salts suitable materials for thermal energy storage. They can be used only as inorganic mixtures or else they can also be used as eutectic mixtures, which involve mixtures of inorganic–inorganic salts or simply a combination of two or more inorganic salts. This research deals with eutectic mixtures, which are 4% KNO3 + 96% H2O, 4% NaHCO3 + 96% H2O, and 2% KNO3 + 2% NaHCO3 + 96% H2O. Three different novel eutectic mixtures were examined and found a suitable mixture for a cold thermal energy system. An efficient phase change approach involving 2% KNO3 + 2% NaHCO3 + 96

Vasanthkumar, P., Santhoshkumar, A., Gopika, P., Murali, M., Meera, C.

SAE TOMORROW TODAY BRIEFS: EV Batteries That Run on Sunshine--Or in the Cold

134606/12/2024

It's no secret that installing EV charging stations can be time-consuming. But what if you could use the power of the sun? Beam Global is doing just that -- not only on land, but in the water and sky as well. Beam's research and work in thermal management enables EV batteries to charge in a hot or cold environments. Using clean energy solutions like solar power, Beam deploys EV charging infrastructure in minutes not months -- with no permitting, no construction, and no electrical work. Listen in as Roberto Baldwin, Sustainability Editor, SAE Sustainable Mobility Solutions, sits down with Said Al-Hallaj, Chief Battery Scientist, Beam Global, to discuss the rapidly deployed and scalable EV charging solutions, the challenges of electrification in the air and water, and the importance of thermal management. For more information on the evolution of sustainability, head on over to sustainablecareers.sae.org. There you can read about how GM is pushing back on media coverage that growth in the

Hineman, Marcie

Multi-Physics Modeling and Optimization Towards a Digital Twin of Quenching Process of Large-Scale Metallic Structures

F-0080-2024-1399

5/7/2024

Quenching is a heat treatment process for the rapid cooling of a metallic workpiece in water, oil, or air to obtain certain desired material properties. It is the most critical step in the sequence of heat-treating operations to preserve the solid solution formed at the solution heat-treating temperature by rapidly cooling to near room temperature. Because of the complex interaction between temperature, phase-transformation, and stress/strain relation that depends on the temperature distribution and the microstructure of the workpiece, there is no performance-informed quenching process that can be applied reliably to reduce the high scrap rate of airframe aluminum forging parts with a significant amount of residual stress and distortion. Since large aluminum forging parts are increasingly used in aerospace structures to enable structural unitization, it is important to construct a digital twin modeling approach to mirror the physical quenching process for minimizing scrap rate

Lua, Jim, Phan, Nam, Piccoli, Joshua, Yan, Jinhui, Karuppiah, Anand, Shrestha, Kalyan

High-Fidelity Digital Twin Autoclave for Quality Informed Composite Fabrication

F-0080-2024-1139

5/7/2024

The Autoclave processing is commonly used in manufacturing high-performance fibre-reinforced thermoset composite components in the aerospace industry. Variations in the cure cycle, sometimes even apparently minor deviations from the prescribed cure cycle, can harm the laminate properties. Given the costly and time-consuming autoclave manufacturing process, there is a strong need to cure the maximum number of parts in the shortest possible time without compromising quality. In order to achieve high-rate automated manufacturing with the optimized autoclave process, it is important to construct a digital twin modelling approach to mirror the physical composite curing process in the virtual domain based on the integration of high-fidelity multi-physics models. The resulting digital twin includes a thermal CFD model, a thermo-chemo-mechanical module, and an efficient and accurate block coupling between these two modules. The customized Abaqus driven by local and spatial variation of the

Lua, Jim, Phan, Nam, Guay, Ian, Yan, Jinhui, Karuppiah, Anand, Shrestha, Kalyan

Lightning Strike Experiments and Their Direct Effects on Flax Fiber-Reinforced Polymer Panels for Rotorcraft Components

F-0080-2024-1307

5/7/2024

This paper experimentally investigates direct effects of lightning strikes on flax fiber-reinforced polymers. Highcurrent artificial lightning strikes are conducted on coupon level to evaluate thermo-mechanical damage and to quantify the sufficiency of copper wire mesh as lightning strike protection (LSP). The dataset shall also serve for verification of prospected numerical simulation. The natural fiber flax, as a sustainable source of composite reinforcement, has been demonstrated to be suitable for semi-structural parts of rotorcraft. However, its low electrical and thermal conductivity requires a functional LSP layer for aviation applications. The test panels are investigated regarding their material combination, stacking sequence and level of LSP. Results show that two as well as three layers of 72 g/m2 copper mesh are not sufficient to withstand the standardized lightning current component A waveform of 200 kA. The high induced currents and low capability of energy dissipation

Gaugelhofer, Lukas, Yavrucuk, Ilkay, Hajek, Manfred, John, Jonas

Numerical analyses of Ad-Blue thawing performance according to EU Norms

2024-26-02631/16/2024

Controlling NOx emission demands is getting more serious with Euro 7 legislation. This in turn brings more focus on SCR (Selective Catalytic Reduction) technologies which uses a eutectic mixture of Urea (67.5%) - Water (32.5%) solution more popularly known as Diesel Exhaust Fluid (DEF/Ad-Blue). Under extreme winter conditions, Ad-Blue freezes as ambient reaches well below the freezing point (-11 deg.C). Due to Legislation requirement (EU), it is a matter of interest to estimate the time required by Ad-Blue to melt the desired volume inside the tank thereby defining overall Melting/Thawing performance. So far, testing has been the primary method for arriving at right melting mechanism and for designing electrical coils or hot coolant lines which is expensive. This paper proposes a novel digital method using 3D CFD tool STAR CCM+ to study the melting behavior of Ad-Blue. The method is characterized by capturing phase change using the popular multiphase (VOF) approach and different modes

GOVINDARAJAN, Vaishali, VARUGHESE, Shibu, Banik, Soumendu, R, Vineeth

Gasoline Particulate Filter Calibration approach for BS6 market

2024-26-01561/16/2024

With the implementation of BS6 standards, there is an increased focus on reducing particulate matter and particulate number emissions from gasoline Direct Injection (GDI) engines. The direct injection process can lead to increased soot formation, which poses environmental concerns. GPFs are effective in capturing particulate matter (PM) and Particulate number (PN) but their calibration is critical to ensure optimal performance and emissions compliance. This paper presents a study on the calibration of Gasoline Particulate Filters (GPF) to comply with Bharat Stage-6 (BS6) emissions norms. The main focus is on thermal management, soot loading, ash loading and the unique challenges faced in the Indian market. Thermal management strategies include active and passive methods to optimize GPF regeneration and prevent thermal degradation. Active RGN mechanism involves advanced control on engine to achieve target temperature and sufficient oxygen to react with soot. Passive RGN occurs during

Arale, Shrikant, B G, Sharath, Chaudhari, Kuldeepak, Madhukar, Prahlad, MY, Raghu

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