Lithium metal structural battery developed with vacuum bagging

Development of structural batteries having outstanding energy storage and load carrying abilities simultaneously are promising to accelerate the light-weighting of automobile and aviation industries. Here, the fabrication of a lithium...

CRUSH CHARACTERISTICS OF ADHESIVELY BONDED COMPOSITE-ALUMINUM TUBES

Tubular members are used in the automotive industry for body, chassis, and powertrain components such as front rails, underbody frames or sub frames, driveshaft structures and space frames. They are also extensively used in buses and other heavy vehicle structures. With focus on light-weighting, there is increasing use of multimaterial structures with aluminum and high-performance composites. Joining a variety of materials with different characteristics and compositions is a major challenge for the design of such structures. Hence, adhesive bonding is emerging as one of the key joining technique for multi-material structures due to their compatibility with commonly used lightweight materials. Since tubular joints in automotive structures may experience crush type load, this study considers the crush characteristics of composite-aluminum tubular adhesive joints using finite element analysis.

Salt Quench Hardening: An Overview

This presentation will provide the general audience with an overview of salt quench hardening, the pros and cons of working with salt, the benefits of salt quenching, and some of the various processes as well as types of equipment used when working with salt quench applications. We will answer the question “why salt?” by comparing it to traditional oil quench applications, by considering the characteristics of salt and how it promotes hardenability, ductility, tensile and yield strength, and by looking at the benefits of salt for distortion control, heat extraction, ease of washing, and the “green” side of recycling. We will address equipment layout configurations and the ancillary pieces of equipment required for an efficient operation, based on production requirements with a consideration of the specific part weight, geometry and annual volume. We will touch on NFPA guidelines and general safety practices. Finally, we will look at various processes associated with quenching in salt – austempering and marquenching, and as we conclude the presentation, we will discuss how material and process changes can lead to engineering optimization opportunities for “light-weighting”, mechanical feature enhancements, and process reduction.

New Generation Press Hardening Steels with Tensile Strength of 1.7-2.0 GPa and Enhanced Bendability

Press hardening steel (PHS) applications predominately use 22MnB5 AlSi coated in the automotive industry. This material has a limited supply chain. Increasing the tensile strength and bendability of the PHS material will enable light-weighting while maintaining crash protection. In this paper, a novel PHS is introduced, and properties are compared to 22MnB5. The new Coating Free PHS (CFPHS) steel, 25MnCr, has increased carbon, with chromium and silicon additions for oxidation resistance. Its ultimate tensile strength (UTS) of 1.7 GPa with bending angle above 55° at 1.4mm thickness improves upon the 22MnB5 grade. This steel is not pre-coated, is oxidation resistant at high temperature, thus eliminating the need for AlSi or shot blasting post processing to maintain surface quality. Microstructural mechanisms used to enhance bendability and energy absorption are discussed for the novel steel. Performance evaluations such as: weldability, component level crush and intrusion testing and e-coat adhesion, are conducted on samples from industrial coils.

A Life Cycle Engineering Perspective on Biocomposites as a Solution for a Sustainable Recovery

Composite materials, such as carbon fibre reinforced epoxies, provide more efficient structures than conventional materials through light-weighting, but the associated high energy demand during production can be extremely detrimental to the environment. Biocomposites are an emerging material class with the potential to reduce a product’s through-life environmental impact relative to wholly synthetic composites. As with most materials, there are challenges and opportunities with the adoption of biocomposites at the each stage of the life cycle. Life Cycle Engineering is a readily available tool enabling the qualification of a product’s performance, and environmental and financial impact, which can be incorporated in the conceptual development phase. Designers and engineers are beginning to actively include the environment in their workflow, allowing them to play a significant role in future sustainability strategies. This review will introduce Life Cycle Engineering and outline how the concept can offer support in the Design for the Environment, followed by a discussion of the advantages and disadvantages of biocomposites throughout their life cycle.

Material Selection Considerations for Lightweight Automotive Bodies

Lightweight is a trend of new vehicle development, driven by government regulations, environmental concerns, and customer needs. A major effort in the automotive industry is on light weighting vehicle bodies. This chapter reviews the various materials, their characteristics, weight reduction potentials, and costs for light weighting vehicle bodies. The chapter also exams the joining technologies on their principles, applications for the lightweight materials, and influencing factors for choosing a joining process. Furthermore, this chapter discusses the development trends of material selection and joining technology applications.