Browse Topic: Manufacturing

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Traceability E-Fuels 20352024-01-3022To be published on 07/02/2024
EU legislation provides for only local CO2 emission-free vehicles to be allowed in individual passenger transport by 2035. In addition, the directive provides for fuels from renewable sources, i.e. defossilised fuels. This development leads to three possible energy sources or forms of energy for use in individual transport. The first possibility is charging with electricity generated from renewable sources, the second possibility is hydrogen generated from renewable sources or blue production path. The third possibility is the use of renewable fuels, also called e-fuels. These fuels are produced from atmospheric CO2 and renewable hydrogen. Possible processes for this are, for example, methanol or Fischer-Tropsch synthesis. The production of these fuels is very energy-intensive and large amounts of renewable electricity are needed. Thus, national production of these fuels in the EU is inefficient in terms of cost and carbon footprint due to the low utilisation rate of renewable energyStoll, Tobias, Kulzer, Andre, Berner, Hans-Juergen
Technical Paper
Automated Park and Charge: Concept and Energy Demand Calculation2024-01-2988To be published on 07/02/2024
In this paper we are presenting the concept of automated park and charge functions in different use scenarios. The main scenario is automated park and charge in production and the other use scenario is within automated valet parking in parking garages. The automated park and charge in production is developed within the scope of the publicly funded project E-Self. The central aim of the project is the development and integration of automated driving at the end-of-line in the production at Ford Motor Company's manufacturing plant in Cologne. The driving function thereby is mostly based upon automated valet driving with an infrastructure based perception and action planning. Especially for electric vehicles the state of charge of the battery is critical, since energy is needed for all testing and driving operations at end-of-line. In addition long shipping times require in combination with a specific state-of-charge requirement at customer delivery a recharging within the productionSturm, Axel Wolfgang, Kascha, Marcel, Mejri, Mohamed Amine, Henze, Roman, Heister, Laura, Mueck, Alexander
Technical Paper
Additively Manufactured Wheel Suspension System with Integrated Conductions and Optimized Structure2024-01-2973To be published on 07/02/2024
Increasing urbanisation and the growing environmental awareness in society require new and innovative vehicle concepts. In the present work, the design freedoms of additive manufacturing (AM) are used to develop a front axle wheel suspension for a novel modular vehicle concept. The development of the suspension components is based on a new method using industry standard load cases for the strength design of the components. To design the chassis components, first the available installation space is determined and a suitable configuration of the chassis components is defined. Furthermore, numerical methods are used to identify component geometries that are suitable for the force flow. The optimisation setup is selected in a way that allows to integrate information, energy and material-carrying conductors into the suspension arms. The conductors even serve as load-bearing structures because of the matching design of the components. High-strength light metals are used to minimise theWeitz, Fabian, Debnar, Christian, Frey, Michael, Gauterin, Frank
Technical Paper
Making modal analysis easy and more reliable – Reference points identification by experimental prestudy2024-01-2931To be published on 06/12/2024
Though modal analysis is a common tool to evaluate the dynamic properties of a structure, there are still many individual decisions to be made during the process which are often based on experience and make it difficult for occasional users to gain reliable and correct results. One of those experience-based choices is the correct number and placement of reference points. This decision is especially important, because it must be made right in the beginning of the process and a wrong choice is only noticeable in the very end of the process. Picking the wrong reference points could result in incomplete modal analysis outcomes, as it might make certain modes undetectable, compounded by the user's lack of awareness about these missing modes. In the paper an innovative approach will be presented to choose the minimal number of mandatory reference points and their placement. While other approaches use results of numerical simulations or rely on a visual evaluation of measurement data by theKamper, Tim, Beljan, Denis, Brücher, Haiko, Wegerhoff, Matthias
Technical Paper
Comparing the NVH behaviour of an innovative steel-wood hybrid battery housing design to an all aluminium design2024-01-2949To be published on 06/12/2024
The production of electric vehicles (EVs) has a significant environmental impact, with up to 50 % of their lifetime greenhouse gas potential attributed to manufacturing processes. The use of sustainable materials in EV design is therefore crucial for reducing their overall carbon footprint. Wood laminates have emerged as a promising alternative due to their renewable nature. Additionally, wood-based materials offer unique damping properties that can contribute to improved Noise, Vibration, and Harshness (NVH) characteristics. In comparison to conventional materials such as aluminum, ply wood structures exhibit beneficial damping properties. The loss factor of plywood structures with a thickness below 20 mm ranges from 0.013 to 0.032. Comparable aluminum structures however exhibit only a fraction of this loss factor with a range between 0.002 and 0.005. In this study, the potential of lightweight wood composites, specifically steel-wood hybrid structures, is investigated in the designWagner, Markus, Baumann, Georg, Lindbichler, Lukas, Klanner, Michael, Feist, Florian
Technical Paper
The irrotational intensity: an efficient tool to understand the vibration energy propagation in complex structures using an FE Model2024-01-2942To be published on 06/12/2024
Although structural intensity was introduced in the 80's, this concept never found practical applications, neither for numerical nor experimental approaches. Quickly, it has been pointed out that only the irrotational component of the intensity offers an easy interpretation of the dynamic behavior of structures by visualizing the vibration energy flow. This is especially valuable at mid and high frequency where the structure response understanding can be challenging. A new methodolodgy is proposed in order to extract this irrotational intensity field from the Finite Element Model of assembled structures such as Bodies In White. This methodology is hybrid in the sense that it employs two distinct solvers: a dynamic solver to compute the structural dynamic response and a thermal solver to address a diffusion equation analogous to the thermal conduction built from the previous dynamic response. The field separation is based on the Helmholtz-Hodge theorem, that ensures the computationsGagliardini, Laurent, Takhchi, Jamal, Sadoulet-reboul, Emeline, Ouisse, Morvan, Bornet, Frederic
Technical Paper
A Finite-Element-Simulation Workflow to Investigate the Aero- and Vibro-Acoustic Signature of an Enclosed Centrifugal Fan2024-01-2940To be published on 06/12/2024
Centrifugal fans are applied in many industrial and civil applications, such as manufacturing processes and building HVAC systems. They can also be found in automotive applications. Noise-reduction mea- sures for centrifugal fans are often challenging to establish, as acous- tic performance may be considered a tertiary purchase criterion after energetic efficiency and price. Nonetheless, their versatile application raises the demand for noise control. In a low-Mach-number centrifugal fan, acoustic waves are predominantly excited by aerodynamic fluctu- ations in the flow field and transmit to the exterior via the housing and duct walls. The scientific literature documents numerous mech- anisms that cause flow-induced sound generation, even though only some are considered well-understood. Numerical simulation methods are widely used to gather spatially high-resolved insights into physical fields. However, for a centrifugal fan, the numerical simulation of the coupled aero- andHeidegger, Patrick, Czwielong, Felix, Schoder, Stefan, Becker, Stefan, Kaltenbacher, Manfred
Technical Paper
Towards the Design-driven Carbon Footprint reduction of Composite Aerospace and Automotive components: An overview2024-37-0032To be published on 06/12/2024
Composite materials, pioneered by aerospace engineering due to their lightweight, strength, and durability properties, are increasingly adopted in the high-performance automotive sector. Besides the acknowledged composite components’ performance, enabled lightweighting is becoming even more crucial for energy efficiency, and therefore emissions along vehicle use phase from a decarbonization perspective. However, their use entails energy-intensive and polluting processes involved in raw material production, in manufacturing processes, and, in particular, in end-of-life disposal. Carbon footprint is the established indicator to assess the environmental impact of climate-changing factors on products or services. Research on different carbon footprint sources reduction is increasing, and even the European Composites Industry Association is demanding the development of specific Design for Sustainability approaches. This paper analyzes the early strategies for providing low-carbon aerospaceDalpadulo, Enrico, Russo, Mario, Gherardini, Francesco, Leali, Francesco
Technical Paper
Development of a Hybrid-Electric Medium-HD Demonstrator Vehicle with a Pent-Roof SI Natural Gas Engine2024-37-0026To be published on 06/12/2024
In response to global climate change, there is a widespread push to reduce carbon emissions in the transportation sector. For the difficult to decarbonize heavy-duty (HD) vehicle sector, lower carbon intensity fuels can offer a low-cost, near-term solution for CO2 reduction. The use of natural gas can provide such an alternative for HD vehicles while the increasing availability of renewable natural gas affords the opportunity for much deeper reductions in net-CO2 emissions. With this in consideration, the US National Renewable Energy Laboratory launched the Natural Gas Vehicle Research and Development Project to stimulate advancements in technology and availability of natural gas vehicles. As part of this program, Southwest Research Institute developed a hybrid-electric medium-HD vehicle (class 6) to demonstrate a substantial CO2 reduction over the baseline diesel vehicle and ultra-low NOx emissions. The development included the conversion of a 5.2L diesel engine to spark-ignitedWallace, Julian, Mitchell, Robert, Rao, Sandesh, Jones, Kevin, Kramer, Dustin, Wang, Yanyu, Chambon, Paul, Sjovall, Scott, Williams, D. Ryan
Technical Paper
Model-Based Algorithm for Water Management Diagnosis and Control for PEMFC Systems for Motive Applications2024-37-0004To be published on 06/12/2024
Water management in PEMFC power generation systems is a key point to guarantee optimal performances and durability. It is known that a poor water management has a direct impact on PEMFC voltage, both in drying and flooding conditions: furthermore, water management entails phenomena from micro-scale, i.e., formation and water transport within membrane, to meso-scale, i.e., water capillary transport inside the GDL, up to the macro-scale, i.e., water droplet formation and removal from the GFC. Water transport mechanisms through the membrane are well known in literature, but typically a high computational burden is requested for their proper simulation. To deal with this issue, the authors have developed an analytical model for the water membrane content simulation as function of stack temperature and current density, for fast on-board monitoring and control purposes, with good fit with literature data. The water flow from the catalyst layer to the GFC through the GDL is modelledSicilia, Massimo, Cervone, Davide, Polverino, Pierpaolo, Pianese, Cesare
Technical Paper
Advanced squeak and rattle noise prediction for vehicle interior development – numerical simulation and experimental validation2024-01-2925To be published on 06/12/2024
Squeak and rattle (SAR) noise audible inside a passenger car causes the product quality perceived by the customer to deteriorate. The consequences are high warranty costs and a loss in brand reputation for the vehicle manufacturer in the long run. Therefore, SAR noise must be prevented. This research shows the application and experimental validation of a novel method to predict SAR noise on an actual vehicle interior component. The novel method is based on non-linear theories in the frequency domain. It uses the harmonic balance method in combination with the alternating frequency/time domain method to solve the governing dynamic equations. The simulation approach is part of a process for SAR noise prediction in vehicle interior development presented herein. In the first step, a state-of-the-art linear frequency-domain simulation estimates an empirical risk index for SAR noise emission. Critical spots prone to SAR noise generation are located and ranked. In the second step, the nonRauter, Andreas, Utzig, Lukas, Weisheit, Konrad, Marburg, Steffen
Technical Paper
Optimization of a Sliding Rotary Vane Pump for Heavy Duty Internal Combustion Engine cooling2024-37-0030To be published on 06/12/2024
The benefits introduced by the replacement of conventional centrifugal pumps with volumetric machines for Internal Combustion Engines (ICEs) cooling were experimentally and theoretically proven in literature. In particular, Sliding Rotary Vane Pumps (SVRPs) ensure to achieve an interesting reduction of ICEs fuel consumption and CO2 emissions. Despite volumetric pumps are a reference technology for ICE lubrication oil circuits, the application in ICE cooling systems still not represent a ready-to-market solution. Particularly challenging is the case of Heavy-Duty ICE due to the wide operating range the pump covers in terms of flow rate delivered. Generally, SVRPs are designed to operate at high speeds to reduce machine dimensions and, consequently, the weight. Nevertheless, speed increase could lead to a severe penalization of pump performance since the growth of the friction losses. They produce wear phenomena which require expensive surface treatments or, more generally, the adoptionFatigati, Fabio, Di Bartolomeo, Marco, Pallante, Francesco, Lo Biundo lng, Giuseppe, Cipollone, Roberto
Technical Paper
Buckling and Post-Buckling Response of 3D Printed Cylindrical Shell with Circular Cutout Under Axial Compression2024-26-0418To be published on 06/01/2024
Despite being ubiquitous elements in aerospace structures, thin cylindrical shells’ catastrophic buckling response under axial compression has still remained an enigma. The recent advancements in theoretical and numerical studies aided in realising the role of localisation in shell buckling. However, the buckling being instantaneous made it unfeasible for the experimental observations to corroborate the numerical results. This necessitates high-fidelity shell buckling experiments using full-filed measurement techniques. Cut-outs are deliberate and inevitable geometrical imperfections in actual structures that could dictate the buckling response. Additive manufacturing makes it feasible to fabricate shells with tailored imperfections and study various conceivable designs. Consequently, to comprehend the effect of circular cutout on the buckling response, cylindrical shells are 3D printed in thermoplastic polyurethane (TPU) with a circular cutout of a certain size that couldRavulapalli, Vineeth, Raju, Gangadharan, Manoharan, Ramji, Naryanamurthy, Vijayabaskar
Technical Paper
Selective Laser Melting Based Additive Manufacturing Process Diagnostics using In-line Monitoring Technique and Laser-Material Interaction Model2024-26-0420To be published on 06/01/2024
Selective Laser Melting (SLM) has gained widespread usage in aviation, aerospace, and die manufacturing due to its exceptional capacity for producing intricate metal components of highly complex geometries. Nevertheless, the instability inherent in the SLM process frequently results in irregularities in the quality of the fabricated components. As a result, this hinders the continuous progress and wider acceptance of SLM technology. Addressing these challenges, in-process quality control strategies during SLM operations have emerged as effective remedies for mitigating the quality inconsistencies found in the final components. This study focuses on utilizing optical emission spectroscopy and IR thermography to continuously monitor and analyze the SLM process within the powder bed, with the aim of strengthening process control and minimizing defects. Optical emission spectroscopy is employed to study the real-time interactions between the laser and powder bed, melt pool dynamicsRaju, Benjamin, Kancherla, Kishore Babu, B S, Dakshayini, Roy Mahapatra, Debiprosad
Technical Paper
Elastomeric Swaging Finite Element Analysis Methodology to Evaluate Structural Integrity of Internal Swaged Joints2024-26-0428To be published on 06/01/2024
In applications demanding high performance under extreme conditions of pressure and temperature, a range of Mechanically Attached Fittings (MAFs) is offered by various Multinational Corporations (MNCs). These engineered fittings have been innovatively designed to meet the rigorous requirements of the aerospace industry, offering a cost-effective and lightweight alternative to traditional methods such as brazing, welding, or other mechanically attached tube joints. One prominent method employed for attaching these fittings to tubing is through Internal Swaging, a mechanical technique. This process involves the outward formation of rigid tubing into grooves within the fitting. One of the methods with which this intricate operation is achieved is by using a drawbolt - expander assembly within an elastomeric swaging machine. Traditionally, elastomeric swaged joints find extensive application among Aerospace Industry Original Equipment Manufacturers (OEMs) and are compatible with materialsSandhu, Taranjeet, Aher, Ravi, Soni, Ravi, Barsawade, Nikhil, Kamthe, Swapnil, Sajjan Phalle, Vijay
Technical Paper
Multi-Scale Modeling of Selective Laser Melting Process2024-26-0415To be published on 06/01/2024
The Selective Laser Melting (SLM) process is employed in high-precision layer-by-layer Additive Manufacturing (AM) on powder bed and aims to fabricate high-quality structural components. To gain a comprehensive understanding of the process and its optimization, both modeling and simulation in conjunction with extensive experimental studies along with laser calibration studies have been attempted. Multiscale and multi-physics-based simulations have the potential to bring out a new level of insight into the complex interaction of laser melting, solidification, and defect formation in the SLM parts. SLM process encompasses various physical phenomena during the formation of metal parts, starting with laser beam incidence and heat generation, heat transfer, melt/fluid flow, phase transition, and microstructure solidification. To effectively model this Multiphysics problem, it is imperative to consider different scales and compatible boundary conditions in the simulations. In this paper, weVarma, Aditya, Ganesh, Kona Veera, Roy Mahapatra, Debiprosad
Technical Paper
Automatic Maneuver Detection in Flight Data using Wavelet Transform and Deep Learning Algorithms2024-26-0462To be published on 06/01/2024
The evaluation of aircraft characteristics through flight test maneuvers is fundamental to aviation safety and understanding flight attributes. This research project proposes a comprehensive methodology to detect and analyze aircraft maneuvers using full flight data, combining signal processing and machine learning techniques. Leveraging the Wavelet Transform, we unveil intricate temporal details within flight data, uncovering critical time-frequency insights essential for aviation safety. The integration of Long Short-Term Memory (LSTM) models enhances our ability to capture temporal dependencies, surpassing the capabilities of machine learning in isolation. These extracted maneuvers not only aid in safety but also find practical applications in system identification, air-data calibration, and performance analysis, significantly reducing pre-processing time for analysts. Moreover, they serve as a foundational component for developing fault-tolerant models, thereby contributing toParihar, Pratik, Kumar, Utsav, Kaliyari, Dushyant, Tk, Khadeeja Nusrath
Technical Paper
Comparative Analysis of Axial Flux and Radial Flux Motors for UAV Propulsion: Design and Suitability Assessment2024-26-0467To be published on 06/01/2024
In the architecture of an Unmanned Aerial Vehicle (UAV), a crucial component responsible for the propulsion system is the electric motor. Over the years, different types of electric motors, including Brushless Direct Current (BLDC), have supported the UAV’s propulsion system in diverse configurations. However, in the context of flux flow, the Radial Flux Permanent Magnet Motor (RFPMM) has been given more priority than the Axial Flux Permanent Magnet Motor (AFPMM) due to its sustainability in design and construction. Nevertheless, the AFPMM boasts higher speed, power density, lower weight, and greater efficiency than the RFPMM, because of its shorter flux path and the absence of end-turn winding. Therefore, this paper focuses on conducting a suitability analysis of an AFPMM as a shaft-connected propeller-mounted motor, with the intention of replacing the RFPMM in UAV applications. The design of the AFPMM, incorporating topologies featuring a one-rotor, one-stator configuration, isC, Carunaiselvane, Kumar, Rajesh
Technical Paper
Design of Mini-Hexapod Rover System for Future Lunar Exploration2024-26-0456To be published on 06/01/2024
Lunar tubes, natural underground structures on the Moon formed by ancient volcanic activity, offer natural protection from extreme temperatures, radiation, and micro-meteorite impacts, making them prime candidates for future lunar bases. However, the exploration of lunar tubes requires a high degree of mobility. Given the Moon's gravity, which is approximately six times weaker than Earth's, efficient navigation across rugged terrains within these lava tubes is achievable through jumping. In this work, we present the design of subsystems for a miniature hexapod rover weighing 1 kg, which can walk, jump, and stow. The walking system consists of two subsystems: one for in-plane walking, employing four single-degree-of-freedom (DOF) legs utilizing the KLANN walking mechanism, and another for directional adjustments before jumping. The latter employs a novel three-DOF mechanism employing a cable pulley mechanism to optimize space utilization. The design of these legs prioritizesShanbhag, Sushanth Suresh, Sharma, Shachindra, Damurothu, Krishna, Sandeep, R
Technical Paper
Generating Reduced-Order Image Data and Detecting Defect Map on Structural Components using Ultrasonic Guided Wave Scan2024-26-0416To be published on 06/01/2024
The paper presents a theoretical framework for the detection and first-level preliminary identification of potential defects on aero-structure components while employing ultrasonic guided wave based structural health monitoring strategies, systems and tools. In particular, we focus our study on ground inspection using laser-Doppler scan of surface velocity field, which can also be partly reconstructed or monitored using point sensors and actuators on-board structurally integrated. Using direct wave field data, we first question the detectability of potential defects of unknown location, size, and detailed features. Defects could be manufacturing defects or variations, which may be acceptable from design and qualification standpoint; however, those may cause significant background signal artifacts in differentiating structure progressive damage or sudden failure like impact-induced damage and fracture. We consider the surface velocity field over continuous time stamps as obtained fromKolappan Geetha, Ganesh, Ravi, Nitin. B, Roy Mahapatra, Debiprosad
Technical Paper
Assessing the Structural Feasibility and Recyclability of Flax/PLA Bio-Composites for Enhanced Sustainability2024-26-0407To be published on 06/01/2024
Bio-composites have gained significant attention within the aerospace industry due to their potential as a sustainable solution that addresses the demand for lightweight materials with reduced environmental impact. These materials blend natural fibers sourced from renewable origins, such as plant-based fibers, with polymer matrices to fabricate composite materials that exhibit desirable mechanical properties and environmental friendliness. The aerospace sector's growing interest in bio-composites originates from those composites’ capacity to mitigate the industry's carbon footprint and decrease dependence on finite resources. This study aims to investigate the suitability of utilizing plant derived flax fabric/PLA (polylactic acid) matrix-based bio-composites in aerospace applications, as well as the recyclability potential of these composites in the circular manufacturing economy. The bio-composite laminate is produced through a compression molding process involving interleaved layersB S, Dakshayini, Kancherla, Kishore Babu, Raju, Benjamin, Roy Mahapatra, Debiprosad
Technical Paper
Empowering Air Travel Accessibility for Passengers with Reduced Mobility (PRM2024-26-0481To be published on 06/01/2024
The abstract presents a comprehensive exploration of enhancing air travel accessibility for passengers with reduced mobility (PRMs) while adhering to the provided guidelines. As the number of PRMs grows consistently, surpassing the general passenger growth rate, the aviation industry faces the challenge of accommodating their distinct needs. This abstract thoroughly examines this pivotal issue. Focusing on safety, the paper emphasizes the responsibility of cabin crew to ensure the well-being of all passengers. Balancing PRMs' seating preferences with effective emergency evacuations becomes a crucial consideration. The abstract delves into potential trade-offs in meeting PRMs' comfort while enabling efficient evacuations, especially on smaller aircraft. Airport security and potential misuse of PRM status are discussed, advocating for rigorous security measures applied universally. The concept of secondary airside wheelchairs is suggested to enhance security during transitions throughsekhar, chandra
Technical Paper
Nickel Alloy, Corrosion- and Heat-Resistant, Seamless Tubing, 72Ni - 15.5Cr - 0.95Cb (Nb) - 2.5Ti - 0.70Al - 7.0Fe (X750), Vacuum Melted, Solution Heat Treated, Precipitation Hardenable to 170 ksi (1172 MPa) Tensile StrengthAMS5583G (Current)05/17/2024
This specification covers a precipitation hardenable corrosion- and heat-resistant nickel alloy in the form of seamless tubingAMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Identification Carbon and Low-Alloy Steels, Corrosion- and Heat-Resistant Steels and Alloys Sheet, Strip, Plate, and Aircraft TubingAMS2807C (Current)05/17/2024
This specification covers procedures for identifying carbon and low-alloy steels, corrosion- and heat-resistant steels and alloys, maraging and other highly alloyed steels, and iron alloy sheet, strip, and plate, and aircraft tubingAMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Steel, Corrosion-Resistant, Sheet, Strip, and Plate 17Cr - 7.1Ni - 1.1Al (Alloy 17-7) Solution Heat Treated, Precipitation HardenableAMS5528K (Current)05/17/2024
This specification covers a corrosion-resistant steel in the form of sheet, strip, and plate 0.005 to 1.000 inches (0.13 to 25.40 mm) in nominal thickness in the solution heat-treated conditionAMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Nickel Alloy, Corrosion- and Heat-Resistant, Welding Wire 57Ni - 19.5Cr - 13.5Co - 4.2Mo - 3.1Ti - 1.4Al - 0.006B Vacuum Induction Melted, Solution Heat TreatedAMS5828H (Current)05/17/2024
This specification covers a corrosion- and heat-resistant nickel alloy in the form of welding wireAMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Aluminum Alloy, Extrusions 6.2Zn - 2.3Cu - 2.2Mg - 0.12Zr (7050-T76511) Solution Heat Treated, Stress Relieved, Straightened, and OveragedAMS4340H (Current)05/17/2024
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing up to 5.000 inches (127.00 mm), inclusive, in nominal diameter or least thickness (see 8.5AMS D Nonferrous Alloys Committee
Material Specification
Aluminum Alloy, Plate (7140-T7651) 6.6Zn - 1.8Cu - 2.0Mg - 0.10Zr Solution Heat Treated, Stress Relieved, and OveragedAMS4408B (Current)05/17/2024
This specification covers an aluminum alloy in the form of plate 4.000 to 10.000 inches (101.6 to 254.0 mm), inclusive, in nominal thickness (see 8.5AMS D Nonferrous Alloys Committee
Material Specification
Magnesium Alloy Welding Wire, 9.0Al - 2.0Zn (AZ92AAMS4395G (Current)05/17/2024
This specification covers a magnesium alloy in the form of welding wire (see 8.5AMS D Nonferrous Alloys Committee
Material Specification
Surface Properties of Shot-Peened and Plasma Sprayed Powder-Coated Alpha-Beta Titanium Alloy Implants2024-01-506005/15/2024
The paramount importance of titanium alloy in implant materials stems from its exceptional qualities, yet the optimization of bone integration and mitigation of wear and corrosion necessitate advanced technologies. Consequently, there has been a surge in research efforts focusing on surface modification of biomaterials to meet these challenges. This project is dedicated to enhancing the surface of titanium alloys by employing shot peening and powder coatings of titanium oxide and zinc oxide. Comparative analyses were meticulously conducted on the mechanical and wear properties of both treated and untreated specimens, ensuring uniformity in pressure, distance, and time parameters across all experiments. The outcomes underscore the efficacy of both methods in modifying the surface of the titanium alloy, leading to substantial alterations in surface properties. Notably, the treated alloy exhibited an impressive nearly 12% increase in surface hardness compared to its untreated counterpartBalasubramanian, K., Bragadeesvaran, S. R., Raja, R., Jannet, Sabitha
Technical Paper
Aerospace & Defense Technology: May 202424AERP0505/09/2024
Explaining MOSA from the Team that Led the Army Aviation Mission Computing Environment Task Order What's the Best DC Motor for Your Commercial Aerospace Application? Aerospace Production: Overcoming Challenges in Composite Machining Understanding the Limits of Artificial Intelligence for Predictive Maintenance Pushing the Limits: Engineering Advanced RF Interconnects to Meet the Challenges of Hypersonic Missile Development Expanding Possibilities for Superconducting Qubits With Niobium Researchers Help Robots Navigate Efficiently in Uncertain Environments A new algorithm reduces travel time by identifying shortcuts a robot could take on the way to its destination. New, Portable Antenna Could Help Restore Communication After Disasters Researchers from Stanford and the American University of Beirut have developed a lightweight, portable antenna that can communicate with satellites and devices on the ground, making it easier to coordinate rescue and relief efforts in disaster-prone areas
Magazine Issue
Nickel Alloy, Corrosion- and Heat-Resistant Seamless Tubing, 72Ni - 15.5Cr - 0.95Cb (Nb) - 2.5Ti - 0.70Al - 7.0Fe (X750), Solution Heat Treated, Precipitation HardenableAMS5582H (Current)05/09/2024
This specification covers a precipitation hardenable, corrosion- and heat-resistant nickel alloy in the form of seamless tubing 0.125 inch (3.18 mm) and over in nominal OD and 0.015 inch (0.38 mm) and over in nominal wall thicknessAMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Machine Requalification Considerations for Fusion-Based Metal Additive ManufacturingARP7064 (Current)05/09/2024
This document defines a recommended practice for addressing metal additive manufacturing (AM) machine requalification for all fusion-based metal AM machines. In general, this applies to powder bed fusion (PBF) and wire- or powder-fed directed energy deposition (DED) technologies. Plasma, electron beam, or lasers are applicable energy source(sAMS AM Additive Manufacturing Metals
Recommended Practice
Experimental Analysis of Heat Transfer Post Quenching of Medium Carbon Steel05-17-03-001905/08/2024
Transient temperature analysis is involved in the thermal simulation of the heat treatment process, in which the hot metal temperature changes with respect to time from an initial state to the final state. The critical part of the simulation is to determine the heat transfer coefficient (HTC) between the hot part and the quenching medium or quenchant. In liquid quenching, the heat transfer between the hot metal part and water becomes complicated and it is difficult to determine HTC. In the current experimentation a medium carbon steel EN 9 rod with a diameter of 50 mm and length 100 mm was quenched in water and ethylene glycol mixture with different concentrations. A part model was created; meshed and actual boundary conditions were applied to conduct computational fluid dynamics (CFD) analysis. In order to validate CFD analysis the experimental trials were conducted. Experimental results showed a reduced cooling rate for the specimen, and also a reduction in heat-carrying capacity ofMutalikdesai, Sachin, Shinde, Tarang, Nanwatkar, Ravikant
Journal Article
Effects of Hard-to-Measure Material Parameters on Clinching Joint Geometries Using Combined Finite Element Method and Machine Learning05-17-03-001805/06/2024
In this article, we investigated the effects of material parameters on the clinching joint geometry using finite element model (FEM) simulation and machine learning-based metamodels. The FEM described in this study was first developed to reproduce the shape of clinching joints between two AA5052 aluminum alloy sheets. Neural network metamodels were then used to investigate the relation between material parameters and joint geometry as predicted by FEM. By interpreting the data-driven metamodels using explainable machine learning techniques, the effects of the hard-to-measure material parameters during the clinching are studied. It is demonstrated that the friction between the two metal sheets and the flow stress of the material at high (up to 100%) plastic strain are the most influential factors on the interlock and the neck thickness of the clinching joints. However, their dependence on the material parameters is found to be opposite. First, while the friction between the two metalNguyen, Duc Vinh, Tran, Van-Xuan, Lin, Pai-Chen, Nguyen, Minh Chien, Wu, Yan-Jiu
Journal Article
Aerospace Production: Overcoming Challenges in Composite Machining24AERP05_0305/01/2024
Composite materials play an important role in aerospace manufacturing. The light weight, durability and ability to create complex shapes from molds make these materials ideal for frames and structural components that enable lighter, more fuel-efficient aircraft. While composite structures can weigh up to 20 percent less than their metal counterparts, these materials can often be more difficult to machine. The extremely abrasive nature of carbon fiber reinforced polymers (CFRPs) will wear down standard cutting tools more quickly than almost any other material. A standard carbide cutting tool may only hold up to cutting a few feet of CFRPs before its dimensional stability fails, while in traditional metal machining that same tool might last 20 to 50 times that before wearing out
Magazine Article
Steel, Corrosion-Resistant, Bars, Wire, Forgings and Forging Stock 17Cr - 0.52Mo (0.95 - 1.20C) (SAE 51440C) for Bearing ApplicationsAMS5880F (Current)05/01/2024
This specification covers a corrosion-resistant steel in the form of bars, wire, forgings, and forging stockAMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Copper, Sheet, Strip, and Plate Soft AnnealedAMS4500L (Current)05/01/2024
This specification covers unalloyed copper in the form of sheet, strip, and plate at least 0.015 inch (0.38 mm) in nominal thicknessAMS D Nonferrous Alloys Committee
Material Specification
Sheet and Plate, Magnesium Alloy 3.0Al - 1.0Zn - 0.20Mn (AZ31B-O) Annealed and RecrystallizedAMS4375N (Current)05/01/2024
This specification covers a magnesium alloy in the form of sheet and plate from 0.016 to 3.000 inches (0.41 to 76.20 mm), inclusive, in thickness (see 8.5AMS D Nonferrous Alloys Committee
Material Specification
Magnesium Alloy, Extrusions, 5.5Zn - 0.45Zr (ZK60A-T5), Precipitation Heat TreatedAMS4352K (Current)05/01/2024
This specification covers a magnesium alloy in the form of extruded bars, rods, wire, tubing, and profiles up to 40 square inches (258 cm2) in cross-sectional area (solids) and up to 8.5 inches (216 mm) OD by 1.188 inches (30.18 mm) wall thickness (tubing) (see 8.5AMS D Nonferrous Alloys Committee
Material Specification
3D Printing Method Builds Structures with Two MetalsTBMG-5069705/01/2024
Washington State University Pullman, WA
Magazine Article
A New Material That Excels at Trapping HydrogenTBMG-5064105/01/2024
University of Wisconsin–Madison engineers have used a spray coating technology to produce a new workhorse material that can withstand the harsh conditions inside a fusion reactor
Magazine Article
Experimental Analysis of Kerf Characteristics of Carbon Fiber-Reinforced Polymer with Abrasive Water Jet Machining05-17-02-001305/01/2024
This research looks into how abrasive water jet machining (AWJM) can be used on carbon fiber-reinforced polymer (CFRP) materials, specifically how the kerf characteristics change with respect to change in process parameters. We carefully looked into four important process parameters: stand-off distance (SOD), water pressure (WP), traverse rate (TR), and abrasive mass flow rate (AMFR). The results showed that as SOD goes up, the kerf taper angle goes up because of jet dispersion, but as WP goes up, the angle goes down because jet kinetic energy goes up. The TR was directly related to the kerf taper angle, but it made the process less stable. The kerf drop angle was not greatly changed by AMFR. When it came to kerf top width, SOD made it wider, WP made it narrower, TR made it narrower, and AMFR made it a little wider. When the settings (SOD: 1 mm, WP: 210 MPa, TR: 150 mm/min, AMFR: 200 g/min) were optimized, the kerf taper angle and kerf top width were lowered. This improved the accuracyChandgude, Abhimanyu, Barve, Shivprakash B.
Journal Article
A Virtual Calibration Strategy and Its Validation for Large-Scale Models of Multi-Sheet Self-Piercing Rivet Connections05-17-03-001604/29/2024
This article presents a strategy for the virtual calibration of a large-scale model representing a self-piercing rivet (SPR) connection. The connection is formed between a stack of three AA6016-T4 aluminum sheets and one SPR. The calibration process involves material characterization, a detailed riveting process simulation, virtual joint unit tests, and the final large-scale model calibration. The virtual tests were simulated by detailed solid element FE models of the joint unit. These detailed models were validated using experimental tests, namely peeling, single-lap joint, and cross-tests. The virtual parameter calibration was compared to the experimental calibration and finally applied to component test simulations. The article contains both experiments and numerical models to characterize the mechanical behavior of the SPR connection under large deformation and failureAndré, Victor, Costas, Miguel, Langseth, Magnus, Morin, David
Journal Article
Influence of Machining Parameters on Tungsten Carbide Inserts in ANSYS Analysis of Maraging Steel Machining2024-01-505704/29/2024
The machining process is employed to transform a workpiece into a predefined geometry with the assistance of a cutting tool. Throughout this process, the cutting tool undergoes various adverse effects, including deformation, stress, thermal gradient, and more, all of which impact tool sharpness, surface finish, and tool life. These outcomes are also influenced by cutting parameters, specifically cutting speed, feed rate, and depth of cut. The present investigation aims to demonstrate the application of ANSYS analysis software in predicting stress, deformation, thermal gradient, and other factors on the tool insert tip for various machining parameters. To achieve this, an experimental setup was arranged to collect cutting force and temperature data using a dynamometer and thermocouples during the machining process of maraging steel with a tungsten carbide tool insert. Experiments were conducted with different combinations of machining parameters using design of experiments (DoE). TheBalasubramanian, K., Jeyakumar, R., Rajendran, C., Kandavalli, Sumanth Ratna
Technical Paper
Se (IV)-Doped Monodisperse Spherical TiO <sub>2</sub> Nanoparticles for Adhesively Bonded Joint Reinforcing: Synthesis and Characterization05-17-03-001704/27/2024
This study focused on the synthesis and characterization of monodisperse spherical TiO2 nanoparticles doped on the surface with Se (IV) in order to increase the mechanical properties of the bonded joint reinforcing. Work will begin with the synthesis of monodisperse quasi-spherical TiO2 nanoparticles with a modal diameter of less than 20 nm, using the sol-gel technique. Se (IV) selenium surface doping changed the specimen’s chemistry and physics. Different initial concentrations of the doping element will be tested. Next, a physicochemical characterization of the different solid systems will be carried out in order to determine the effect of the doping element on the properties of titanium dioxide. Their morphology and size will be studied through transmission electron microscope observations; volume chemical composition by X-ray diffraction analysis, EDX (energy-dispersive X-ray), and XRF (X-ray fluorescence). The careful selection of 4% and 6% concentrations produced the optimumHadjez, Fayssal, Maouche, Hichem, Boumediri, Haithem, Chorfi, Sofiane, Boukelia, Taqiy Eddine
Journal Article
Titanium Alloy Bars, Forgings, and Flash-Welded Rings, 5Al - 2.5V - 4Sn - 1Co - 0.8Fe AnnealedAMS6903 (Current)04/25/2024
This specification covers a titanium alloy in the form of bars, forgings, and flash-welded rings up through 12.000 inches (304.80 mm), inclusive, in diameter or least distance between parallel sides, and stock of any size for forging or flash-welded rings. Bars, forgings, and flash-welded rings with a nominal thickness of 3.000 inches (79.20 mm) or greater shall have a maximum cross-sectional area of 113 square inches (729 cm2) (see 8.5AMS G Titanium and Refractory Metals Committee
Material Specification
Aluminum Alloy, Extruded Profiles (2395-T84), 3.95Cu - 1.15Li - 0.3Ag - 0.5Mg - 0.1Zr, Solution Heat Treated, Stress Relieved by Stretching, and AgedAMS4359A (Current)04/25/2024
This specification covers an aluminum alloy in the form of extruded rods, bars, and profiles (shapes) 0.040 to 1.500 inches (1.02 to 38.10 mm), inclusive, in thickness, and produced with maximum cross-sectional area of 23.25 square inches (15000 mm2) and a maximum circumscribing circle diameter (circle size) of 15.5 inches (394 mm) (see 2.4.1 and 8.6AMS D Nonferrous Alloys Committee
Material Specification
Aluminum Alloy Sheet, 4.4Cu - 1.5Mg - 0.60Mn (2024; -T4 Flat Sheet), Solution Heat Treated, High FormabilityAMS4297C (Current)04/25/2024
This specification covers an aluminum alloy in the form of sheet 0.020 to 0.128 inch (0.51 to 3.25 mm), inclusive, in nominal thickness (see 8.5AMS D Nonferrous Alloys Committee
Material Specification
Aluminum Alloy, Coiled Sheet, Alclad, 4.4Cu - 1.5Mg - 0.60Mn (Alclad 2024; -T4 Coiled Sheet), Solution Heat TreatedAMS4475C (Current)04/25/2024
This specification covers an aluminum alloy in the form of alclad coiled sheet from 0.010 to 0.128 inch (0.25 to 3.25 mm), inclusive, in thickness supplied in the -T4 temper (see 8.5AMS D Nonferrous Alloys Committee
Material Specification
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