Papers by Keyword: Automotive Applications

Abstract: In this study, the microstructure of prepared AMCs with the homogenous distribution of fly ash analyzed using optical microscope. The microstructure having refinement of structure with the decreasing of Si-needle structure and increasing the area of eutectic α-Al matrix as shown in Figure 3. Besides, as the increasing amount of fly ash incorporated, there are more petal-like dark structure existed in the microstructure. The density of the AMCs decreased as the incorporation of fly ash increased. While the hardness strength of the AMCs increased with the incorporation of fly ash. The addition of fly ash particles improved the physical and mechanical properties of the AMCs.

Abstract: The development of new biocomposites and efficient manufacturing methods that are suitable for series processing is the purpose of the current sub-project C4 of the Excellence Cluster MERGE, sponsored by DFG (Deutsche Forschungsgemeinschaft). Two different types of materials are combined: bio-based thermoplastic polymers such as bio-polyethylenes or bio-polyamides and renewable reinforcing materials such as thin wood veneer or unidirectional flax fibers. To achieve a high-efficiency in terms of mass-production, reproducibility and flexibility, it is required to perform several steps in the realization of semi-finished and final products. The improvement of the adhesion at the interface of the components, the implementation of continuous processes, in order to increase energetically the yielding, and the final design, through several methods, for future potential applications are so many perspectives to achieve.

Abstract: Resistivity against intergranular corrosion (IGC) is one of the major requirements for AlMgMn 5xxx-series alloys for automotive chassis applications. In 5xxx alloys IGC is caused by the formation of β-Al₅Mg₃ precipitates along the grain boundaries. Todays 5xxx alloys for chassis applications have been developed such that under specific test conditions they will not exceed a certain mass loss by IGC. However, current developments in the automotive industry will lead to an increased temperature load on chassis parts, in particular for front axle applications in the vicinity of the car engine. Therefore it is to be expected that the properties of the existing 5xxx series alloys will not be sufficient any more. Certain alloy elements, including Mn, Cr, Cu and Zn, alter type and morphology of the Mg-bearing precipitates and, hence, reduce the sensitivity against IGC. The present study was aimed at developing a series of Zn-containing Al alloys which are free of IGC, while maintaining mechanical properties of current 5xxx chassis alloys. Alloy development was performed by micro-chemistry simulation with the aim to avoid the formation of the detrimental β-Al₅Mg₃ precipitates. Eventually a series of three alloys was cast and processed on lab scale and tested for mechanical properties and resistivity against IGC after application of various critical time/temperature scenarios in order to validate that the newly developed alloys are free of IGC.

Abstract: The natural fibre composite materials are nowadays playing a vital role in replacing the conventional and synthetic materials for industrial applications. This paper proposes a natural fiber composite made of Abaca fibre as reinforcing agent with Epoxy resin as the matrix, manufactured using Hand Lay-up method. Glass Fiber Reinforced Plastics (woven rovings) are used to improve the surface finish and impart more strength and stiffness to natural fibers. In this work, the fibers are arranged in alternative layers of abaca in horizontal and vertical orientation. The mechanical properties of the composite are determined by testing the samples for tensile and flexural strength. It is observed that the tensile strength of the composite material is dependent on the strength of the natural fiber and also on the interfacial adhesion between the reinforcement and the matrix. The composite is developed for automobile dashboard/mudguard application. It may also be extended to biomedical, electronics and sports goods manufacturing. It can also be used in marine products due to excellent resistance of abaca to salt water damage since the tensile strength when it is wet.

Abstract: The interest of the automotive industry on biodegradable and green composites is increasing dramatically due two environmental legislation that obliges automakers to reduce the disposal of waste from vehicles [1]. As an answer to this recent demand several research groups are working on the development of these composites. This work shows the development of a loudspeaker front made of two different biodegradable composites: PLA (polylactic acid) and SCA (blend of starch and cellulose acetate) reinforced with different percentages of cellulose spent fibres. The composites were previously extruded on a counter-rotating twin screw extruder and injection moulded into tensile specimens. The mechanical properties of the produced tensile specimens were assessed with an Instron Universal Testing Machine as well as the morphological aspects of the materials, studied with optical and scanning electron microscopies. After these preliminary set of tests, the best composites were chosen to produce the final parts (loudspeaker front). These parts were injection moulded on a Ferromatik Milacron K85 injection moulding machine (850 kN clamping force) and subjected to a wide set of automotive tests to evaluate their performance. The best materials for this application proved to be the PLA reinforced composites, although there is still a large window for improvement of properties, based on the engineering of the matrix/reinforcement interface and also on the improvement of the thermal properties of the PLA material.

Abstract: Heat-treatable Al-Mg-Si aluminum alloys for automotive body panel applications are shipped and formed in T4 temper while still formable and are subsequently given a bake cycle to increase strength by age hardening while the paint is cured. However, the hardening response during the rather short industrial paint-bake is impaired upon natural ageing after the solution treatment. It is thus essential to counteract the adverse effect of natural ageing on bake hardening. While this is often accomplished by an additional ageing cycle before the paint-bake treatment, reversion treatments ought to be used once substantial natural ageing has first taken place to improve the bake hardening response of a twin-roll cast 6016 sheet. The present work was undertaken to improve the paint bake response of a twin-roll cast 6016 sheet by employing reversion treatments before the paint-bake cycle. Reversion treatments between 200°C and 250°C was effective in improving the bake hardening response of the twin-roll cast 6016 sheet which, when processed without reversion, failed to meet in-service strength requirements with a rather poor bake hardening response of 35 MPa.

Abstract: Light weight engineering and composite technologies are key strategies in modern product development in mechanical engineering as well as in biomedical applications, where innovation is driven by novel material concepts and surface functionalities. Designed or customized surface properties by advanced coating technologies are an important discipline in this context. Ceramic, metallurgical and cermet layers can be manufactured in a most appropriate way by high energetic thermokinetic deposition techniques like plasma spraying, electric arc and last not least by supersonic flame spraying (HVOF). These technologies perform high deposition rates, high flexibility to use various materials and their combinations and applications in micro to macro scale products. The final properties of the coatings and layer composites do not just depend on the properties of the combined materials but, as in the case of ceramic coated light metals, are distinctly affected by the occurring residual stresses and their interaction with operational load stresses. With respect to the complex geometries of most components, their dimensional and positional tolerances a further strong influence of the robot kinematics of the plasma or HVOF torches during coating manufacturing is observed. By combining the expertise in materials and manufacturing engineering coatings and composites with high performance and reliability can be achieved. This is shown in the development of functionally coated cylinder liners and crankcases for ultra light weight engines as well as for ceramic coated bioinert and biodegradable substrates in medical surgery. It will be shown that cast engine block bores can be directly coated by using an automated HVOF process, obtaining improved coating results. The internal coating process by hypersonic flame spraying is a superior technological alternative to the APS process for high quality cylinder liner and engine crankcase applications. The applications of such ceramic and cermet coatings are not limited to automotive and biomedical applications, i. e. for wear and friction properties or biomedical compatibility, but can be used for tailored thermophysical, electrophysical or catalytic properties in various technical systems.