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Climatic conditions in parts of North America have created a need for cold weather testing of automotive products for this market. To fulfill this need, a Cold Weather Test Facility has been constructed and is in operation at Kapuskasing, in Northern Ontario. The need for the facility, its design and operation, the types of tests conducted, and typical test results obtained are discussed.

The purpose of this study was to define the performance of 1973 vehicles (meeting the requirements of FMVSS 215) in terms of collision losses. The study addresses both unrepaired and repaired damage. In terms of overall dollars per car-year, the results fail to show a difference in losses between 1973 model year vehicles and 1971 model year vehicles.

This paper reports on research which examined the effectiveness of 1974 automobile bumpers in terms of occupant safety and automobile damageability. Static and dynamic tests were performed by attaching a height measuring device on the front and rear bumpers of 1974 domestic automobiles. The static test results showed effective bumper height match. The dynamic test results showed that 21% of bumpers could mismatch when the rear (colliding) vehicle is pitched due to braking and 77% of bumpers could mismatch when both vehicles are pitched due to braking. Occupant safety is discussed in terms of both the positive and negative effects of the new bumpers for all collision speeds. The effect on override/underride collision frequency and passive restraint (air bag) system activation is examined. The tradeoffs of decreased frequency of damage to vehicles and increased costs to replace the new bumpers when they are damaged in high speed collisions are discussed.

With the development of the addition-type polyimide resins, a need arose for a coupling agent that would improve the performance of the fiber-resin interface under thermal stress. Research work was carried out to develop such a material and resulted in a new coupling agent for use at high temperatures. The test data generated from glass fiber reinforced composites using this new coupling agent, and the study of the interface using the scanning electron microscope, demonstrate an improvement in the cohesive and interfacial shear of the glass fiber-resin matrix. This development has provided the designer with a material that retains its structural integrity under extreme thermal conditions.

This paper presents the theoretical dynamic properties of an elastomeric-pneumatic isolator with orifice-type relaxation damping. The elastomeric portions of the isolator serve to contain the pressurized air, contribute elastic stiffness, and act as a cushioning and motion-limiting “snubber” in cases where severe shock transient excitations exist. The pressurized air contained within the isolator serves to support the entire static load, contribute stiffness, and provide orifice-type relaxation damping. The resulting design concept results in a low profile, low natural frequency, and very stable isolator for shock and vibration isolation. The objective of the isolator design is to provide the maximum degree of vibration and shock attenuation of typical vehicle excitations to the vehicle operator at the frequencies where the human body is most sensitive to dynamic excitations.

Difficulties of measuring safety problems related to human factors aspects of vehicle controls and displays are discussed and illustrated with examples. A review of National Highway Traffic Safety Administration (NHTSA)-sponsored control/display research dealing with some of these problems is presented. The review describes the objectives, methodology, key findings, and application of the results of the research. Finally, future research needs are outlined.

A study on the temporary viscosity loss under high shear rates of engine lubricants was started in order to: 1. Set up a new viscometer, more correlate with the engine than the present ones. 2. Clarify the influence of this phenomenon on the lubricant performances. Preliminary results on a pressoviscometer are discussed. Namely it is underlined that the temporary viscosity loss affects both multigrade and unigrade oils, even if at different levels, and in different ways.

Several polymeric materials were developed and evaluated for possible inclusion in the neck structure of state-of-the-art anthropomorphic dummies. These included three types of foam-polyvinylchloride, polyethylene, and polyurethane, and two flexible polymers-polyurethane and a polyvinylchloride chlorinated polyethylene blend (PVC-CPE). Two materials, the polyurethane elastomer and the PVC-CPE blend, were found to be satisfactory in their dynamic response. Because of the ease of casting, the polyurethane material will be used in the GMR 1 state-of-the-art dummy.

Water-atomized nickel-molybdenum alloy (0.5 Ni-0.5 Mo) powder was blended with graphite for 0.4% carbon, then pressed into preforms (1.5 X 2 X 5 in). The preforms were hot formed to full density via a variety of processing conditions (various degrees of flow, sintering temperature, and sintering atmosphere). Impact specimens were excised and tested over a range of temperatures to determine the ductile-to-brittle transition temperature. All impact specimens had ductile failure at room temperature. In general, increased deformation increased the room-temperature and low-temperature impact strengths by eliminating particle boundaries and elongating the inclusions. High temperature sintering reduced the oxygen content and improved the impact strength by reducing the number of crack-initiating inclusions. Jominy hardenability test results were unaffected by various sintering conditions because the amount of easily oxidizable alloying elements was kept to a minimum.

This paper traces the more than 20-year history of fiberglass reinforced plastic (FRP) as the primary body material for the Chevrolet Corvette. Reasons for the original decision to use FRP are reviewed, followed by a discussion of the difficulties encountered in design, manufacturing techniques, and material compounding. These problems, and the solutions to them, include the progression from the original wet-mat material to low-profile systems. Sheet molded compounds (SMC) are discussed as non-low profile and low-profile applications. Unresolved production problems and outlined with a review of industry attention necessary to assure continued FRP application to Corvette body panels. This paper also discusses the design and application of flexible facias used on both front and rear-end bumper systems and the use of plastic as a bumper energy-managing system.

A few P/M fabricators currently are producing alloy parts which have high hardness in the as-sintered condition. These parts are intended for applications requiring high-wear resistance in service. The chemistries of the alloys used generally are proprietary. The objective of this paper is to describe for P/M fabricators and end users the metallurgical principles involved in designing the alloy chemistry to produce parts of this type; that is, the types and amounts of alloys are described which will suitably alter the phase transformation characteristics so that martensitic microstructures are produced during sintering. An understanding of these principles could lead to expanded usage of alloy wear-resistant P/M parts.

A comparison of standard methods of joining P/M structures, as well as new techniques. The porosity of a P/M part is no longer a problem when joining P/M to P/M or P/M to wrought. These joints will be as strong or stronger than the P/M material. The systems give the design engineer more flexibility.

The Ford Motor Company has developed a mathematical model utilizing electronic data processing techniques to calculate the potential savings to owners of automobiles equipped with energy absorbing bumpers. This model can be used to measure the economic effectiveness of alternative bumper performance requirements and/or system design proposals. Base data for the model has been obtained from surveys conducted by Ford of damage to pre-FMVSS 215 controlled vehicles. A description of the technique utilized to predict bumper system economic effectiveness and the results of Ford Motor Company's bumper cost-effectiveness studies are contained in this report.

The major factors influencing the cost-benefit relationship of improved bumper systems are discussed. Evidence is presented which demonstrates that energy-absorbing bumper designs have proved effective in reducing the frequency of crash damage, especially damage from low-speed crashes. Among the statistical sources utilized are State Farm's Current Model Year Study, Survey of Unrepaired Damage, Highway Loss Data Institute reports, and Insurance Institute for Highway Safety crash test results. Although the improved bumper systems are proving effective, the maximum potential cost savings are not yet being realized by consumers. This situation should change as standardization of bumper heights becomes more prevalent and as better data on the costs of improved bumper systems becomes available.

The sound pressure level (SPL) measured at a given point varies as a motor vehicle goes through a pass-by noise test such as SAE J986a. The tests described in this paper were intended to assess the magnitude and variability of different motor vehicle noise measurements. All factors which might cause variation in the received SPL were either controlled or monitored. This study was designed to quantify the effects on SPL from wind turbulence.

As the compliance with noise legislation became more difficult, Ford exhaust system development engineers increasingly encountered variances not only from vehicle-to-vehicle, but on the same vehicle tested in different locations. As a result, a series of tests were conducted to establish the correlation among various sites for vehicle exterior noise measurements. The purpose of this paper is to present the results and the method developed to achieve the correlation in terms of the following: 1. Ford and site equipment differences 2. Driver differences 3. Differences between site physical qualities Seven sites were evaluated in the program where seven vehicles were used with a good spread in exterior noise levels. A representative correlation plot is also presented which can be used to predict the expected noise level of any vehicle at any one of these test sites knowing the level obtained at the Ford site.

A series of road, engine, chassis dynamometer, and accessory power consumption tests was conducted in order to characterize the fuel economy of 1973 standard and intermediate size vehicles. Devices and systems which appeared to offer fuel economy benefits were evaluated by means of an analytical procedure. The study was limited to hardware which could be in production by the 1980 model year. The evaluation procedure was based on urban and steady speed operation, and the effects of compliance with future emission standards were included. Combinations of individual improvements were selected and applied to the same vehicle. The evaluation procedure was repeated, and fuel economy improvements of 30 to 70% were predicted by comparison with 1973 model year vehicles.

The fuel economy data obtained from the emission tests run by the U.S. Environmental Protection Agency (EPA) have been used to show passenger car fuel economy trends from model year 1957 to present. This paper adds the 1975 model year to the historical trend and concentrates on comparisons between the 1975 and 1974 models. Methodologies which allow different 1975 vs 1974 comparisons to be made have been developed. These calculation procedures allow the changes in fuel economy to be determined separately for emission control systems, new engine-vehicle combinations and model mix shifts. Comparisons have been calculated not only for the fleet as a whole but for each of the 13 manufacturers who were certified as of the time this paper was prepared. The net change in fuel economy for the fleet has been estimated at +13.8% comparing the 1975 models to the 1974 models assuming no model mix change occurs.

The European passenger car engine lubrication requirements are not the same as the American requirements. The differences are determined by the eingine design trends, the nature of fuels used and the type of service. The European engine and petroleum industries have undertaken the study of engine oil evaluation tests that meet European requirements. On the basis of the present standardized tests, engine manufacturers have recently proposed a specification for crankcase oils. This paper discusses particularly the European tests as to repeatability, reproducibility and correlation with service. Mention is also made of the recent European proposals for revision of the SAE Crankcase Oil Viscosity Classification.

A CEC Investigation Group has examined temperatures in European gasoline engines. A survey showed top quartile average temperatures of 275°C (top ring groove), 147°C (sump) and 163° (cam/follower oil gallery and main bearing exit), under high speed driving conditions. Forecasts indicated sump temperatures would increase by 10-15°C, partly related to emissions control systems. Consequent problems were predicted as wear, scuffing, oil oxidation, ring sticking, high oil consumption, and bearing/seal distress. Development targets for lubricant high temperature performance tests are discussed, and the severities of a number of possible ring stick tests are compared. A similar CEC Survey concerned high-speed diesel engines. This covered both small passenger car, light van diesels, and larger truck diesels. Increasing ring and oil sump temperatures were identified.