Ceramic automotive Stirling engine program

The Ceramic Automotive Stirling Engine Program evaluated the application of advanced ceramic materials to an automotive Stirling engine. The objective of the program was to evaluate the technical feasibility of utilizing advanced ceramics to increase peak engine operating temperature, and to evaluate the performance benefits of such an increase. Manufacturing cost estimates were also developed for various ceramic engine components and compared with conventional metallic engine component costs

Prediction of Surface Quality Using Artificial Neural Network for the Green Machining of Inconel 718

Inconel 718 is a nickel-based heat resistant super-alloy (HRSA) that is widely used in many aerospace and automotive applications. It possesses good properties like corrosion resistance, high strength, and exceptional weld-ability but it is considered as one of the most difficult alloys to cut. Recently researchers have focused on employing many machining strategies to improve machinability of Inconel 718. This research work presents the experimentation of wet milling of Inconel 718 using a carbide tool with biodegradable oil. Surface quality is the major aspect of machinability. Hence input parameters such as depth of cut, cutting speed, and feed rate are considered to study their effect on surface quality. Nine experimental runs based on an L9 orthogonal array are performed. Additionally, analysis of variance (ANOVA) is applied to identify the most significant factors among cutting speed, feed rate, and depth of cut. Moreover, this research work presents the Artificial Neural Network (ANN) model for predicting the surface roughness based on experimental results. The ANN based-decision-making model is trained by using acquired experimental values. Visual Gene Developer 2.0 software package is used to study the efficiency of ANN. The presented ANN model demonstrates a very good statistical performance with a high correlation and extremely low error ratio between the actual and predicted values of surface roughness and tool wear

Improvement of powertrain mechatronic systems for lean automotive manufacturing

In recent years, the increasing severity of emission standards forced car manufacturers to integrate vehicle powertrains with additional mechatronic elements, consisting in sensors, executors and controlling elements interacting with each other. However, the introduction of the best available ecological devices goes hand in hand with the legislation and/or limitations in different regional markets. Thus, the designers adapt the mechatronic system to the target emission standards of the produced powertrain. The software embedded into the Engine Control Unit (ECU) is highly customized for the specific configurations: variability in mechatronic systems leads to the development of several software versions, lowering the efficiency of the design phase. Therefore the employment of a standard for the communication among sensors, actuators and the ECU would allow the development of a unique software for different configurations; this would be beneficial from a manufacturing point of view, enabling the simplification of the design process. Obviously, the new software must still guarantee the proper level of feedbacks to the ECU to ensure the compliance with different emission standards and the proper engine behavior. The general software is adapted to the powertrain: according to the specific target emission standard, some control elements may not be necessary, and a part of the software may be easily removed. In this paper, starting from a real case-study, a more general methodology is proposed for configurations characterized by different powertrain sets and manufacturing line constraints. The proposed technique allows to maintain the accuracy of the control system and improve process efficiency at the same time, ensuring lean production and lowering manufacturing costs. A set of mathematical techniques to improve software efficacy is also presented: the resulting benefits are enhanced by software standardization, because the design effort may be shared by the largest possible number of applications

Study of ionic contamination in electronic product assembly

Dissertação de mestrado em Chemical Analysis and Characterization TechniquesThe ever-growing demand for better PCB (printed circuit board) performance as well as component miniaturization and increasing density, are all challenges the automotive industry is facing nowadays. However, these alterations in the PCB layout alongside changes in production materials and techniques may jeopardize product reliability. One of the factors that has the ability to threaten PCB functioning is the introduction of ionic contaminants that increase the probability of electrochemical reactions and premature circuit failures. Methods have been created along the years in order to evaluate the presence of these contaminants on printed boards; one of them is the ROSE (Resistivity of Solvent Extract) test. This thesis aimed to study the ionic contamination in electronic product assembly using the CM22 contaminometer, a ROSE test machine. Essentially, this project was divided in two studies. The first one was the study of ROSE machine response and establishment of parameters to test its performance at Bosch Car Multimedia Portugal S.A. The results revealed that although the relation between the machine response and the dissolved contamination was linear, there was some disparity in values of PCBs from the same product family. The temperature and regeneration time of the extraction bath were identified as possible influencers of this discrepancy. Further tests showed temperature is not a significant factor for this behaviour and, at lower contamination levels, the regeneration time has little impact. The second study intended to evaluate the ionic contamination levels of printed circuit boards in 5 different stages of their production run. This research revealed that the ROSE levels of the PCBs obtained from the supplier decrease during the first steps of the process. Solder paste application, component insertion and reflow steps do not introduce much ionic residues on the board surface. Yet, the most important conclusion to this study is that the flux used for rework and selective soldering greatly increases surface contamination presence. In conclusion, the CM22 ROSE contaminometer is suitable to monitor processes in assembly plants. It can detect contamination trends at a process line and can be used as process control tool especially in a no-clean soldering process like the one used in Bosch. For this reason, the evaluation of ionic content should be carried out in different stages of PCBA production since it can be very deceptive to do them only after reflow process as it normally done.A crescente demanda por melhor desempenho de PCBs (placas de circuito impresso), bem como a miniaturização de componentes e o aumento da sua densidade, são desafios que a indústria automóvel enfrenta atualmente. No entanto, as alterações no seu design juntamente com as mudanças nos materiais e técnicas de produção podem comprometer a fiabilidade destas placas. Um dos fatores que tem a capacidade de ameaçar o funcionamento de um PCB é a introdução de contaminantes iónicos capazes de criar falhas elétricas no circuito. Vários métodos foram criados para avaliar a presença destes contaminantes em placas impressas; um deles é o teste ROSE (Resistividade do Extrato Solvente). Esta tese teve como objetivo o estudo da contaminação iónica na montagem de produtos eletrónicos utilizando o contaminometer CM22, um dispositivo de teste ROSE. Para isto, primeiro estudou-se a resposta da máquina ROSE e estabeleceu-se parâmetros para testar o seu desempenho na Bosch Car Multimedia Portugal S.A. Os resultados revelaram que embora a relação entre a resposta do aparelho e a contaminação dissolvida seja linear, existiu alguma disparidade nos valores de placas da mesma família. A temperatura e o tempo de regeneração do banho foram identificados como possíveis influenciadores desta discrepância. Testes adicionais mostraram que a temperatura não influencia este comportamento e, em níveis de contaminação mais baixos, o tempo de regeneração tem pouco impacto. O segundo estudo pretendia avaliar os níveis de contaminação iónica de placas de circuito impresso em 5 fases diferentes da sua montagem. Este estudo permitiu verificar que o PCB obtido do fornecedor possui um nível de ROSE que diminui ao longo dos primeiros passos do processo. As etapas de aplicação da pasta de solda, inserção dos componentes e refluxo não introduzem muitos resíduos à superfície da placa. No entanto, a conclusão mais importante deste estudo é que o fluxo usado para retrabalho e soldadura seletiva aumentam muito a contaminação na superfície das placas. Em conclusão, o contaminometer CM22 é adequado para monitorizar os processos de fabrico. Ele pode detetar tendências de contaminação na linha de produção e pode ser usado como ferramenta de controlo de processo, especialmente num processo sem limpeza como o da Bosch. Por esse motivo, a avaliação do conteúdo iónico deve ser realizada em diferentes etapas da produção de PCBAs, dado que pode ser enganoso fazê-lo somente após o refluxo, como normalmente é

Properties of silicon carbide fiber-reinforced silicon nitride matrix composites

The mechanical properties of NASA Lewis developed SiC/RBSN composites and their thermal and environmental stability havd been studied. The composites consist of nearly 30 vol pct of aligned 142 micron diameter chemically vapor-deposited SiC fibers in a relatively porous silicon nitride matrix. In the as-fabricated condition, the unidirectional and 2-D composites exhibited metal-like stress-strain behavior, graceful failure, and showed improved properties when compared with unreinforced matrix of comparable density. Furthermore, the measured room temperature tensile properties were relativley independent of tested volume and were unaffected by artifical notches normal to the loading direction or by thermal shocking from temperatures up to 800 C. The four-point bend strength data measured as a function of temperature to 1400 C in air showed that as-fabricated strength was maintained to 1200 C. At 1400 C, however, nearly 15 pct loss in strength was observed. Measurement of room temperature tensile strength after 100 hr exposure at temperatures to 1400 C in a nitrogen environment indicated no loss from the as-fabricated composite strength. On the other hand, after 100 hr exposure in flowing oxygen at 1200 and 1400 C, the composites showed approximately 40 pct loss from their as-fabricated ultimate tensile strength. Those exposed between 400 to 1200 C showed nearly 60 pct strength loss. Oxidation of the fiber/matrix interface as well as internal oxidation of the porous Si3N4 matrix are likely mechanisms for strength degradation. The excellent strength reproducibility, notch insensitivity, and high temperature strength of the composite makes it an ideal candidate for advanced heat engine applications provided coating or densification methods are developed to avoid internal oxidation attack

Fretting corrosion of tin-plated separable connectors used in automotive applications

Greater demands are being placed on the separable connector to perform with higher reliability in harsher automotive environments. Corrosion in its various forms is a major mechanism which affects contact reliability and this current work focuses on surface oxidation and the related phenomenon of fretting corrosion, from which hot dipped tin (HDT), a common automotive connector coating, is known to suffer. For an in-depth study of high contact resistance, in both static conditions and when subjected to relative micromovement, an interdisciplinary approach was necessary, drawing on the results of published work carried out in the fields of contact and surface science, corrosion and tribology. [Continues.

No Fault Found events in maintenance engineering Part 2: Root causes, technical developments and future research

This is the second half of a two paper series covering aspects of the no fault found (NFF) phenomenon, which is highly challenging and is becoming even more important due to increasing complexity and criticality of technical systems. Part 1 introduced the fundamental concept of unknown failures from an organizational, behavioral and cultural stand point. It also reported an industrial outlook to the problem, recent procedural standards, whilst discussing the financial implications and safety concerns. In this issue, the authors examine the technical aspects, reviewing the common causes of NFF failures in electronic, software and mechanical systems. This is followed by a survey on technological techniques actively being used to reduce the consequence of such instances. After discussing improvements in testability, the article identifies gaps in literature and points out the core areas that should be focused in the future. Special attention is paid to the recent trends on knowledge sharing and troubleshooting tools; with potential research on technical diagnosis being enumerated

The electrodeposition and characterisation of compositionally modulated tin-cobalt alloy coatings as lead-free plain bearing material

Traditionally, lead-based bearing overlays dominate the commercial automotive market and it has been proven that an excellent combination of properties can be attained through their use. However, lead is a toxic metal and a cumulative poison in humans. According to the European Union End-of-Life Vehicle (ELV) Directive proposed in 1997, vehicles that registered in'all the member states after 1st July 2003 should contain no lead, mercury, cadmium and hexavalent chromium. In this study, a new sulphate-gluconate electrolyte was used to produce multilayer SnCo coatings, aimed at a lead-free overlay for future market use. Tin-cobalt compositionally modulated alloy (CMA) coatings produced from sulphategluconate electrolytes have been previously examined as a potential replacement for lead-free bearing overlays [1]. However, some obstacles may exist which limit their potential use on an industrial scale. For example, long electroplating times are required to produce a thick coating which is very undesirable from an industrial viewpoint, and also the possible elemental interdiffusion occurring in the coating system under engine operating temperatures could rapidly deteriorate the coating properties. In addition, there is an increasing demand from automotive industry to further improve bearing overlay properties, for example for high performance and high compression ratio engines... cont'd