Search Results for structural automotive components

High-volume additive manufacturing (AM) for structural automotive applications, along the lines of economically viable technologies such as powder metallurgy, castings, and stampings, remains a lofty goal that must be realized to obtain the well-known advantages of AM. This article presents two key opportunities for AM related to automotive applications, specifically within the realm of metal laser powder-bed fusion: alloys and product designs capable of high throughput. The article also presents the general methodology of alloy development for automotive AM. It provides examples of unique designs for reciprocating components in elevated-temperature applications that are also exposed to demanding tribological conditions. The article also discusses the future of AM for automotive applications.

This article provides an overview of the principle forms of corrosion that can occur on automotive aluminum components and offers general guidelines on how best to avoid these situations. It discusses the most common forms of aluminum corrosion such as stress-induced corrosion, cosmetic corrosion, crevice corrosion, and galvanic corrosion.

Structural applications for advanced ceramics include mineral processing equipment, machine tools, wear components, heat exchangers, automotive products, aerospace components, and medical products. This article begins with an overview of the wear-resistant applications and the parameters affecting wear of ceramics, namely, hardness, thermal conductivity, fracture toughness, and corrosion resistance. The next part of the article addresses temperature-resistant applications of advanced ceramics. Specific applications of ceramic materials addressed include cutting tools, pump and valve components, rolling elements and bearings, paper and wire manufacturing, biomedical implants, heat exchangers, adiabatic diesel engines, advanced gas turbines, and aerospace applications.

This article provides a discussion on the structural ceramics used in gas turbine components, the automotive and aerospace industries, or as heat exchangers in various segments of the chemical and power generation industries. It covers the fundamental aspects of chemical corrosion and describes the corrosion resistance characteristics of specific classes of refractories and structural ceramics. The article also examines the prevention strategies that minimize corrosion failures of both classes of materials.

Resin transfer molding (RTM) and structural reaction injection molding (SRIM) are two similar processes that are well suited to the manufacture of large, complex, and high-performance structures. This article discusses the similarities and differences of RTM and SRIM processes and the unique design considerations with respect to the physical properties, geometry, surface quality, process economics, equipment, and tooling of a component that should be considered in choosing RTM or SRIM over other competing processes for fabricating reinforced components.

This article discusses the advantages of polymer matrix composite for automotive application in terms of design drivers, noise, vibration, harshness efficiency, process materials property constraints, safety and reliability, design optimization, structural and appearance requirements, recyclability, and processability. It describes the properties of high-volume composites used in automotive industries. The article provides a discussion on state-of-the-art and developing technologies in automotive field.

This article begins with a description of indirect and direct semisolid metalworking processes. It then provides information on alloy compositions of common aluminum semisolid metalworking alloys and primary die-cast magnesium alloys in a tabular form. The article describes the macroscopic examination of defects, which occur in semisolid metalworking with illustrations. It discusses the macroscopic examination of gating systems and semisolid feedstocks. The article also provides information on feedstock microstructures, direct semisolid metalworking component microstructures, and indirect semisolid metalworking component microstructures of series 300 aluminum casting alloys and magnesium die-casting alloys.

This article provides an introduction to the concepts discussed in the articles under the Section “Recycling and Disposal of Composites” in ASM Handbook, Volume 21: Composites. This Section presents the reader the most recent developments in the open-and closed-loop recycling of polymer and metal matrix composites.

The compression molding process is most commonly called the sheet molding compound (SMC) process in reference to the precursor sheet molding compound material it uses. This article discusses the types of materials used for sheet manufacture, and describes the manufacturing and processing parameters of SMC components, providing details on tooling and process advantages and limitations. The article provides a general overview of the types of compression molding processes, including structural compression molding and thermoplastic compression molding.

This article describes the types of repair and presents reasons for avoiding damage to a structure or component during repair. It discusses the major standardization issues with emphasis on design, repair materials, repair techniques, and inspection.

The commonly used nondestructive testing of cast products include liquid penetrant inspection, radiographic inspection, fluoroscopic inspection and automated defect recognition, ultrasonic inspection, eddy current inspection, process-controlled resonant testing (PCRT), leak test, and electrical conductivity measurements. This article summarizes the application of these nondestructive tests to castings. It also tabulates a partial list of automotive part types and materials amenable to PCRT and lists the potential limitations to the use of PCRT.

This article begins with a brief history of composite materials and discusses its characteristics. It presents an introduction to the constituents, product forms, and fabrication processes of composite materials. The article concludes with a discussion on the applications of organic-matrix, metal-matrix, and ceramic-matrix composites.

This article discusses the commonly encountered forms of automotive body corrosion. The corrosion forms include general or uniform corrosion, cosmetic or under-film corrosion, galvanic corrosion, crevice corrosion, poultice or under-deposit corrosion, and pitting corrosion. Corrosion-resistant sheet metals, such as electrogalvanized steel, hot dip galvanized steel, and hot dip galvannealed steel, are reviewed. The article provides information on the paint and sealant systems for corrosion control in automotive body applications.

Titanium has been recognized as an element with good mechanical and physical properties, alloying characteristics, and corrosion resistance. Providing an outline of general characteristics and types of titanium alloys, this article discusses the contemporary technology of titanium along with its market developments. It also discusses the application of titanium and titanium alloys in corrosive environments and in aerospace and automotive industries. The article describes the developments in titanium processing and materials technologies, which include the development of sponge production and melting processes, oxide dispersion-strengthened alloys by powder metallurgy techniques, titanium-base intermetallic compounds, and titanium-matrix composites.

The primary motivation for the insertion of metal-matrix composites (MMCs) into aeronautical systems is the excellent balance of specific strength and stiffness offered by MMCs. This article provides information on the aerostructural, aeropropulsion, and aeronautical subsystem applications of MMCs. The applications include ventral fin, fuel access door covers, helicopter blade sleeve, fan exit guide vane, nozzle actuator piston rod, nozzle actuator links, T-1 racks, and hydraulic manifold.

This article characterizes the physical differences between powder metallurgy (PM) and wrought or cast materials, as they apply to joining. It discusses acceptable joining procedures and techniques, including welding and brazing and solid-state methods. Information on the weldability of various PM materials is presented. The article also describes the effects of porosity on several important properties that affect the welding characteristics.

This article discusses the properties and uses of structural ceramics and the basic processing steps by which they are made. It describes raw material preparation, forming and fabrication, thermal processing, and finishing. It provides information on the composition, microstructure, and properties of aluminum oxides, aluminum titanate, silicon carbide, boron carbide, zirconia, silicon nitride, silicon-aluminum-oxynitride, and several ceramic composites. It also explains how these materials maintain their mechanical strength and dimensional tolerances at high temperatures and how some of their shortcomings are being addressed.

Metal injection molding (MIM) is a metalworking technology that has its origins as a commercial technology only dating back to the early 1970s. This article explores why the MIM is the preferred solution for many fabricated components. It illustrates the MIM components required for different end-use markets such as electronics and telecommunications, medical, automotive, power hand tools, industries, and firearms.