Papers by Keyword: Automotive Components

Abstract: This case study focuses on the laboratory examination and material analysis of welded components in automotive production. The investigation included metallographic analyses, microstructural evaluations, and non-destructive testing methods to assess weld integrity. Key issues identified were the presence of thermal distortions, incomplete welds, and material defects such as micro-cracks and porosity. A detailed metallographic study revealed that improper cooling rates significantly affected the heat-affected zone (HAZ) and weld microstructure, leading to weaknesses in material strength and increased susceptibility to fatigue. Variations in cooling water flow during the welding process were examined, showing that an intermediate cooling flow rate produced the most consistent microstructural properties. The analysis also indicated the presence of stress concentrators at weld interfaces, which may lead to premature failure under operational stresses. Recommendations include optimizing cooling rates and post-weld heat treatment to enhance material resilience, ensuring long-term durability and performance of welded assemblies.

Abstract: Now, worldwide, the Lean Manufacturing system represents the most comprehensive management philosophy within a manufacturing process. One of the basic principles of Lean Manufacturing is 5S process which involves the risks and wastes eliminating and it is considered a key of worker and equipment’s safety. Therefore, during the last years, 5S was expanded to 6S by the Safety adding. Thus, in this paper aspects about 6S process implementation on a manufacturing company of automotive components is presented. The monthly implementation extent of each 6S process indicators from 2013 until now is described, especially on the production lines of the factory. Finally, the major benefits of the introduction of the 6S principles in the company are highlighted.

Abstract: The finite element modeling and analysis have been performed to investigate the effects of nitriding, cold rolled and shot peening on fatigue life of an automotive lower suspension arm component which fabricated of SAE1045 steel. The finite element analysis (FEA) results indicate a great effect for all surface finish parameters on fatigue life. It shows that nitriding increased the fatigue life of the component better than shot peening, while cold rolled effect was between them. In a nut shell, nitriding can be considered as the best surface treatment to improve the fatigue life of the automotive lower suspension arm which fabricated of SAE1045 steel.