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The paper describes many of the methods of fabricating and finishing fiberboard parts for the automotive industry. Fabricating methods include die-cutting, crease bending, forming, fastening, and adhesive bonding. Finishing methods discussed are paint roll coating, spray painting, printing, and embossing. The equipment and tooling required are also described.

As the world is going through an evolutionary development in most of the science fields, there is an essential and exceptional demand for higher efficiency power generators to recover the thermal losses. Recently thermoelectric materials have attracted extensive attention for this purpose. The recent advancement in nanotechnology has a remarkable impact on thermoelectric materials development. This resulted in nano structured materials whose thermoelectric properties exhibit a great challenge to its bulk form, such as Silicon nanowires (SiNWs). Silicon nanowires are promising thermoelectric materials as they offer large reductions in thermal conductivity over bulk Si without significant decrease in the electrical conductivity. In the present work silicon nanowires have been implemented in fabricating a thermoelectric device which can be employed in different applications, such as engines, to recover part of the energy lost in these applications.

Concerning the fabrication of advanced components of dense silicon nitride, many methods of approach have been reported on in literature. To date, none of these attempts for the fabrication of turbine rotors has been considered feasible. The HIP process, it is believed, can offer an economically viable solution for fabrication of advanced ceramic components when the following reasons are considered: a) hot isostatic pressing is a well established technique. b) dense silicon nitride can be produced without any additives. c) fully isotropic dense silicon nitride is achieved. d) no reaction with capsule material. e) high M.O.R. values at high temperatures. f) consistently high Weibull m-module. g) very high creep resistance. The HIP process implies that even monolithic turbine rotors can be fabricated to final shape. The principle of the HIP process allows production of a large number of components simultaneously, thus offering possibilities for economic production on a large scale.

Familiarity with beryllium metal machining and handling characteristics places the material in favorable perspective with conventional materials. The stability, coefficient of expansion, and thermal conductivity of beryllium are very favorable to achieving and maintaining size control. Extensive use in the aerospace industry has assisted in development of allied processes that further enhance the achievements in fabrication techniques. This paper shows the evolution of fabrication considerations from procurement through completion of parts. Interim processes and surface treatments will be discussed, featuring some applications.

This paper discusses fabrication results experienced with HY-140 steel flight type pressure vessels. HY-140 steel is a recently developed quenched and tempered alloy (5Ni-CR-Mo-V) structural steel with a yield strength of 140,000 psi. Fabrication techniques applied, the tooling used, and the problems encountered are described in detail.

Tetra-Core is the name given to a fiber composite-material developed by the U.S. Army Aviation Materiel Laboratory, Fort Eustis, Va. This report discloses the initial studies conducted at the University of Kansas on Tetra-Core, including fabrication methods, analytical strength analyses, and experimental test results. The Tetra-Core composite is formed by stacking oriented, spaced-fiber lamina in a repeating -60, 0, +60 deg pattern. Layers are offset slightly as the stacking occurs to produce a tetrahedrally shaped element. An improved fabrication loom was conceived and tested. The loom concept is predicated on the fact that the intersection of two planes is a straight line. In the case of Tetra-Core, planes are formed by the buildup of lamina, intersecting to produce tetrahedrally shaped elements. The straight lines formed at these intersections are at an angle of 35 deg 15 min from the vertical.

The following paper has been prepared to describe the procedures used to fabricate and assemble a lightweight demonstration vehicle, built under contract to Ford Motor Company. G.F.R.P. (Graphite Fiber Reinforced Plastic), the specified material for the major body components, made it necessary to combine state-of-the-art aerospace manufacturing methods with current automotive prototype technology to ensure successful completion of the project. Major areas of emphasis include; master tooling aid development, high temperature epoxy molds, component fabrication, component subassembly and body assembly. These areas will be discussed in detail, along with the completion and final assembly of the lightweight vehicle.

Stringent emission standards are driving the development of diesel-fuel injection concepts to mitigate in-cylinder formation of particulates. While research has demonstrated significant reduction in particulate formation using micro-orifice technology, implementation requires development of industrial processes to fabricate micro-orifices with diameters as low as 50 μm and with large length-to-diameter ratios. This paper reviews the different processes being pursued to fabricate micro-orifices and the advanced techniques applied to characterize the performance of micro-orifices. The latter include the use of phase-contrast x-ray imaging of electroless nickel-plated micro-orifices and laser imaging of fuel sprays at elevated pressures. The experimental results demonstrate an industrially viable process to create small uniform orifices that improve spray formation for fuel injection.

Conventional materials like steel, brass, aluminum etc will fail without any indication, cracks initiation, propagation, will takes place with a short span. Now-a-days to overcome these problem, conventional materials are replaced by hybrid composite material. Not only have this conventional material failed to meet the requirement of high technology applications, like space applications and marine applications and structural applications in order to meet the above requirements new materials are being searched. Hybrid composites materials found to the best alternative with its unique capacity of designing the materials to give required properties and light weight. This paper aims to preparing hybrid composite using artificial fibers. Epoxy as resin and glass fiber as fiber for artificial hybrid composite to make a laminate for preparing leaf spring.

Composites materials are substituting constituents for traditional materials due to their remarkable properties, and the addition of nanoparticles gives a new development in the material domain. The nanoparticles influence on fabrication and machinability investigation study is essential as the composites to be used in applications like automotive and aerospace. The current study investigates the machinability characteristics of Al2219 based metal composites reinforced with nanoparticles of SiN/MoS2. Al2219- reinforcements (SiN and MoS2) composites are fabricated by the method of stir casting. Four different compositions (Al2219/SiN (2 wt% and 4 wt%), , Al2219/2 wt.% SiN/ 2 wt.% MoS2, Al2219/2 wt.% MoS2) are fabricated by varying the different weight percentages of nanoparticles reinforcements. An attempt is made to study the investigation analysis of force, surface roughness, and tool wear using CNC machine lathe to consider the effect of cutting speed, cutting depth, and samples.

In the present experimental investigation magnesium based alloy was prepared by mixing magnesium powder and aluminium powder in the ratio 65:35. The prepared magnesium alloy is used as the matrix material. Metal matrix composites were prepared by stir casting route. The composite was prepared by reinforcing 50 nm alumina nanoparticle so that the final composite contains 5, 10 and 15 wt.% alumina. Mechanical properties such as tensile strength, yield strength, impact strength and hardness were evaluated. Significant improvement was observed in impact strength and hardness value. The result showed that magnesium alloy with 5 wt.% alumina nanoparticle has a maximum impact strength of 25.2 J and hardness value 63.86 Hv respectively. Tensile strength and yield strength shows marginal increase in value.

Metal matrix composites were produced by the PRIMEX™ pressureless metal infiltration process. Properties of the composites were determined as a function of particulate loading, filler type, alloy chemistry, and test temperature. Using the property data, a generic brake caliper bridge geometry was designed and modeled. The results of the modeling suggested that composite caliper bridges can be equivalent in stiffness to ductile iron components at only 43% of the mass, and equivalent in stiffness to aluminum components at only 60% of the mass. In addition, composites containing unreinforced regions (i.e., areas without ceramic particulates) were fabricated to facilitate drilling and tapping at attachment locations. The strength of the threads in these regions was evaluated and compared with thread strengths in iron, Al alloy, and monolithic metal matrix composite.

The fabrication process and mechanical testing procedures used by the Frankford Arsenal in production of 105mm sintered iron rotating bands are discussed. It was demonstrated that 105mm bands can be fabricated to meet the class 3 density range of the current military specification (MIL-R-11073) using conventional sintering temperatures (2050°-2100°F) and sintering atmospheres (dissociated ammonia). The major processing requirement was that density must be closely controlled and kept in the upper portion of the density range, approximately between 6.00 and 6.19 g/cc. Two commercial reduced type iron powders were found to be suitable for the production of these bands. The existing methods of test for tensile strength and ductility of bands in the specification appear adequate. A more sophisticated hydrostatic type testing device did not yield more consistent or uniform test data.

Thermacore, Inc. along with the Idaho National Engineering Laboratory (INEL) is developing a Thermionic Heat Pipe Module (THPM) for use with small, Thermionic Space Nuclear Power Systems. The THPM concept is a core length, cylindrical thermionic diode with a near-isothermal heat pipe emitter sleeve coupled to reactor fuel by radiation, and a heat pipe collector which also forms the waste heat radiator. The design allows for independent, non-nuclear development and testing of the THPM hardware for later integration into the nuclear reactor. A hardware development program is currently underway to demonstrate key feasibility components and to fabricate and test prototype THPMs for application to the Small Externally-Fueled Heat Pipe Thermionic Reactor (SEHPTR) concept. This paper describes the scope and status of the THPM development program at Thermacore.

Hydrogen fuel cell powered systems might soon replace the conventional combustion engines used in today's vehicles. Fuel cells hold a great deal of promise for mobile applications including vehicles because they are environmentally friendly and can provide an alternative power supply. They may prove to be the keystone in making traditional electric vehicles a feasible everyday and long-range alternative to conventional combustion driven vehicles. One example of this type of electric vehicle is the New Jersey Venturer, which was equipped with a PEM fuel cell system to demonstrate the use of this new technology.

At the last ESV conference in Kyoto, the Laboratory of UTAC had proposed a work that has permitted the characteristics of a mobile deformable barrier to be defined. After discussion at the European Experimental Vehicles Committee (EEVC) and study of proposals from different members of the Group of Rapporteurs on Crashworthiness (GRCS) of Geneva, a design of a mobile deformable barrier has been defined. To obtain the prescribed force-deflection curves of each part of the front impactor, the use of honeycomb materials has been studied by the Laboratory of UTAC.

Generally brake pads are manufacturing by use of asbestos materials, that materials are chemically harmful and toxic nature to affect the human health. The present investigation is to fabricates polypropylene composites with mixing constant volume [5 vol.%] of alumina nano particles and different volume percentages [0%, 5%, 10% & 15%] of basalt Fiber by hand layup compression technique. The wear characteristics of polypropylene matrix composites were tested by dry sliding condition. The test was carried out pin on disc apparatus, configured with hardened steel counter-face at elevated temperature. The load was applied 10 N to 30 N with the interval of 10 N and varying of sliding speed 300 rpm to 900 rpm with the interval of 300 rpm for the time period of 0-180 sec. The wear rate was decreases with addition of alumina nano particle and the frictional force was increases due to basalt Fiber content present in the composites.

In this work, a detailed process for manufacturing 3D alumina composite microengine pistons is presented. A novel moulding process is developed for shaping alumina composites into accurate micrometer-sized parts with a combination of softlithography micromoulding techniques and colloidal ceramic powder process. Ultrathick SU-8 UV-lithography is used for making master moulds followed by mirror duplication of PDMS softmoulds. A preceramic coating resin (PCR) was used as the binder instead of the traditionally organic binders and the PCR turns into an additive to the composite after the sintering process. The sedimentation of Al2O3/acetone suspensions has been characterized with varying poly vinyl pyrrolidone (PVP) as a dispersant. Optimized PCR and curing conditions have been investigated in the soft moulding process, and prove successful in achieving dense and uniform microcomponents.

The following paper has been prepared to describe the procedures used by the Vought Corporation to fabricate automotive body components in graphite reinforced plastic for the Ford Motor Company Graphite 1979 Ford LTD. This effort was a joint venture by the Milford Fabricating Company - a subsidiary of the Budd Company - and the Vought Corporation. Graphite Fiber Reinforced Plastic, the specified material for the major body components made it necessary to unite proven aerospace methods with current automotive prototype technology to ensure successful completion of the project. Areas to be discussed will be the master tooling aid development, high temperature epoxy molds, and component fabrication.

The more industrialized society is, the more cast iron chips - by products of industry - are produced. Many investigations and development activites on recycling the cast iron chips by powder metallurgy process were made. In this paper, the effects of alloyed powder such as PASC 45, SUS 410L, Fe-Mo, and Fe-Ni powder on the cast iron powders which were made from the cast iron chips of the cylinder block, were studied. The PASC 45, Fe-Mo, and Fe-Ni powder increased the mechanical properties, but the SUS 410L powder deteriorated the mechanical properties. The sintered materials made from the cast iron powders with these alloyed podwers showed higher wear quality as materials of engine valve guide and tappet than the conventional materials.