Advanced Manufacturing Technology in the Automotive Industry

A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: closed (25 November 2020) | Viewed by 22380

Special Issue Editor

Department of Mechanical Engineering, ISEP–School of Engineering, Polytechnic of Porto, 4200-072 Porto, Portugal
Interests: tribology; coatings; manufacturing processes
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The automotive industry remains one of the most competitive sectors in the world economy. From Ford’s mass production system to customized production, it has been a long way marked by very interesting technological advances, which are giving rise nowadays to the fourth industrial revolution, usually known as Industry 4.0. Furthermore, materials and manufacturing systems have registered a strong evolution, increasing the mechanical resistance of alloys, improving the corrosion resistance of ferrous alloys, increasing the use of non-ferrous alloys, etc. However, the technology used in production in the automotive industry has also been deeply improved, increasing the overall quality and enhancing the productivity and flexibility of manufacturing systems, ensuring better quality and also reducing the costs. This Special Issue intends to aggregate a significant number of technological advances in manufacturing systems related to the automotive industry, through high-quality papers able to describe the scientific and technical advances in this field. Papers regarding the investigation of new metallic materials for the automotive industry, research into the heat treatment of alloys devoted to the automotive industry, advances in manufacturing processes related to the automotive industry, the development of new equipment able to improve manufacturing processes in the automotive industry, and so on, will be welcome.

Prof. Francisco J. G. Silva
Guest Editor

Keywords

  • Automotive industry
  • Manufacturing processes
  • Welding
  • Machining
  • Foundry
  • Metal forming processes
  • Materials characterization
  • Heat-treatments
  • Light-weight alloys
  • Automated equipment

Published Papers (6 papers)

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Research

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26 pages, 8806 KiB  
Article
Comparison of Different Manufacturing Processes of AISI 4140 Steel with Regard to Surface Modification and Its Influencing Depth
by Florian Borchers, Brigitte Clausen, Sandro Eckert, Lisa Ehle, Jeremy Epp, Simon Harst, Matthias Hettig, Andreas Klink, Ewald Kohls, Heiner Meyer, Markus Meurer, Bob Rommes, Sebastian Schneider and Rebecca Strunk
Metals 2020, 10(7), 895; https://doi.org/10.3390/met10070895 - 05 Jul 2020
Cited by 24 | Viewed by 4101
Abstract
The surface and subsurface conditions of components are significant for their functional properties. Every manufacturing process step changes the surface condition due to its mechanical, chemical and/or thermal impact. The depth of the affected zone varies for different machining operations, and is predetermined [...] Read more.
The surface and subsurface conditions of components are significant for their functional properties. Every manufacturing process step changes the surface condition due to its mechanical, chemical and/or thermal impact. The depth of the affected zone varies for different machining operations, and is predetermined by the process parameters and characteristics. Furthermore, the initial state has a decisive influence on the interactions that lead to the final surface conditions. The aim of the investigation presented here is to compare the influence of the load characteristics over the depth applied to manufactured components by several different machining operations and to determine the causing mechanisms. In order to ensure better comparability between the surface modifications caused by different machining operations, the same material was used (AISI 4140; German steel grade 42CrMo4 acc. to DIN EN 10083-3) and annealed to a ferritic-pearlitic microstructure. Based on interdisciplinary cooperation within the collaborative research center CRC/Transregio 136 “Process Signatures”, seven different manufacturing processes, i.e., grinding, turning, deep rolling, laser processing, inductive heat treatment, electrical discharge machining (EDM) and electrochemical machining (ECM), were used, and the resulting surface zones were investigated by highly specialized analysis techniques. This work presents the results of X-ray measurements, hardness measurements and electron microscopic investigations. As a result, the characteristics and depths of the material modifications, as well as their underlying mechanisms and causes, were studied. Mechanisms occurring within 42CrMo4 steel due to thermal, mechanical, chemical or mixed impacts were identified as phase transformation, solidification and strengthening due to dislocation generation and accumulation, continuum dynamic recrystallization and dynamic recovery, as well as chemical reactions. Full article
(This article belongs to the Special Issue Advanced Manufacturing Technology in the Automotive Industry)
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15 pages, 2480 KiB  
Article
Optimization Method of Abrasive Water Jet Cutting of Welded Overlay Materials
by Sorin Adrian Barabas and Adriana Florescu
Metals 2019, 9(10), 1046; https://doi.org/10.3390/met9101046 - 26 Sep 2019
Cited by 7 | Viewed by 3670
Abstract
The great advantages of abrasive water jet cutting (AWJC) led to a rapid development of technology. The necessity of studying the process for different materials with weld overlay layers appeared due to the more widespread use of the process of jet cutting. Also, [...] Read more.
The great advantages of abrasive water jet cutting (AWJC) led to a rapid development of technology. The necessity of studying the process for different materials with weld overlay layers appeared due to the more widespread use of the process of jet cutting. Also, weld overlay is used widely in order to increase the durability of products used in the automotive industry. The complexity of shape, surface integrity, rapid processing, easy programming, low costs, and large flexibility of AWJC technology depends on the optimization of functional parameters and correct setting of machinability of cutting materials is one of the most important. A method of optimizing the process is the correct identification of machinability of welded workpieces with different hardness in layers. This research presents the new method and the experiments that validate the theoretical modeling. Average difference between the theoretical and the experimental values of machinability is small and lead to accuracy of results and demonstrates that this method can be used in practice. Full article
(This article belongs to the Special Issue Advanced Manufacturing Technology in the Automotive Industry)
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12 pages, 9258 KiB  
Article
The Optimum Process to Produce High-Strength Cast/Forged Al–8%Zn–2.5%Mg–1%Cu Alloy
by Teng-Shih Shih, Ei-Ting Kwang and Yung-Sen Huang
Metals 2019, 9(9), 970; https://doi.org/10.3390/met9090970 - 03 Sep 2019
Cited by 3 | Viewed by 2575
Abstract
Al–8Zn–2.5Mg–1Cu alloy casting blocks were subjected to homogenization and annealing. The treated blocks were then held at different temperatures and forged in different dies to obtain 20 mm-thick plates. After T73 heat treatment, the plates were cut and machined to obtain tensile bar [...] Read more.
Al–8Zn–2.5Mg–1Cu alloy casting blocks were subjected to homogenization and annealing. The treated blocks were then held at different temperatures and forged in different dies to obtain 20 mm-thick plates. After T73 heat treatment, the plates were cut and machined to obtain tensile bar samples that were further subjected to tensile and potentiodynamic polarization tests. Upon analyzing the experimental results, the subzero-treated and forged samples (SO) developed fine grains in their matrix and displayed yield stress (YS) about 400 MPa and an elongation of 11%. The hot-forged samples (HC) displayed a relatively higher YS slightly >440 MPa and a lower elongation of 4%. The intermetallic compound particles confined to the HC decreased its corrosion resistance to be worse than that of the SO. All anodized and sealed samples effectively improved their corrosion resistance. Due to its fine grains, the anodized SO sample produced a higher Icorr than the anodized HC sample. Full article
(This article belongs to the Special Issue Advanced Manufacturing Technology in the Automotive Industry)
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18 pages, 6820 KiB  
Article
Experimental Study and Numerical Simulation of the Intermittent Feed High-Speed Grinding of TC4 Titanium Alloy
by Jun Yi, Wei Zhou and Zhaohui Deng
Metals 2019, 9(7), 802; https://doi.org/10.3390/met9070802 - 21 Jul 2019
Cited by 10 | Viewed by 3431
Abstract
This paper proposes intermittent feed high-speed grinding, which shows considerable advantages in terms of reducing grinding temperature, relieving grinding wheel blockage and improving workpiece surface integrity. In this grinding, the continuous feed mode of the workpiece is changed into the normal feed + [...] Read more.
This paper proposes intermittent feed high-speed grinding, which shows considerable advantages in terms of reducing grinding temperature, relieving grinding wheel blockage and improving workpiece surface integrity. In this grinding, the continuous feed mode of the workpiece is changed into the normal feed + fast retreat reciprocating feed mode by a fast linear feed worktable. By reasonably setting the normal feed distance of single grinding, the action time of the grinding wheel and workpiece is reduced, so that the grinding heat transfer process does not reach a stable state, reducing the grinding temperature during single grinding. Besides this, the surface temperature is cooled to nearly room temperature and the grinding wheel is flushed by the timely retreating of the grinding wheel to allow the grinding fluid to enter the grinding zone fully, which greatly reduces the phenomenon of heat accumulation and grinding wheel loading. An intermittent feed high-speed grinding experiment on Ti-6Al-4V (TC4) titanium alloy was systematically carried out, and the influence of the grinding parameters on grinding force and grinding temperature was deeply analyzed. The instantaneous grinding temperature field and thermal stress field of TC4 titanium alloy in intermittent feed high-speed grinding were constructed with the finite element method. The surface morphology of the grinding wheel and TC4 titanium alloy specimens after intermittent feed grinding were analyzed and were compared with those after traditional continuous grinding. It was found that the curves of the grinding force and temperature varied with time in the process of machining, consisting of many “pulse” peaks. Under the same grinding parameters, the magnitude of the grinding force is the same as that of continuous grinding. In a certain range, the grinding temperature is greatly affected by the single feed distance and the interval time. The numerical simulation results are in good agreement with the experimental results, and the error is controlled within 12%. Compared with traditional high-speed grinding, under the same process parameters, the grinding temperature is greatly reduced, the surface integrity of the workpiece is better, and the clogging of the grinding wheel is greatly reduced. Full article
(This article belongs to the Special Issue Advanced Manufacturing Technology in the Automotive Industry)
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13 pages, 9980 KiB  
Article
Connection Status Research of the Resistance Spot Welding Joint Based on a Rectangular Terminal Electrode
by Xiaoqi Zhang, Lingbo Wei, Guocheng Xu and Chunsheng Wang
Metals 2019, 9(6), 659; https://doi.org/10.3390/met9060659 - 05 Jun 2019
Cited by 1 | Viewed by 2375
Abstract
Rectangular terminal electrode is adopted in this research to conduct a resistance spot welding (RSW) process on stainless steel plate. The connection status of RSW joints under different welding current, time, and pressure were studied, and revealed how the rectangular terminal electrode shape [...] Read more.
Rectangular terminal electrode is adopted in this research to conduct a resistance spot welding (RSW) process on stainless steel plate. The connection status of RSW joints under different welding current, time, and pressure were studied, and revealed how the rectangular terminal electrode shape and its dimensions influence the RSW joint dimensions. The process analysis results showed that the RSW nuggets welded with rectangular terminal electrode are normally elliptical in shape, and the dimensions of the long axis direction and the short axis direction have a certain proportion. As the welding current increases, the nuggets dimensions in long direction increase first and then decrease, and the internal grain structure also varies. As the welding time increases, the nugget size in long direction increase first and then steady and rarely splash occurs. As the welding pressure increase, the nugget dimensions in long direction increase first and then decrease, and the splash easily occurs under large welding pressure. However, when the welding pressure is too small, the unique adjacent double fusion nugget formed. By adopting proper welding parameters, the nugget size and quality can be controlled. This provides an important basis for the application of rectangular terminal electrode in RSW welding process. Full article
(This article belongs to the Special Issue Advanced Manufacturing Technology in the Automotive Industry)
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Review

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27 pages, 5576 KiB  
Review
New Developments and Future Trends in Low-Temperature Hot Stamping Technologies: A Review
by Chenpeng Tong, Qi Rong, Victoria A. Yardley, Xuetao Li, Jiaming Luo, Guosen Zhu and Zhusheng Shi
Metals 2020, 10(12), 1652; https://doi.org/10.3390/met10121652 - 08 Dec 2020
Cited by 18 | Viewed by 5171
Abstract
Improvement of the hot stamping process is important for reducing processing costs and improving the productivity and tensile properties of final components. One major approach to this has been to conduct all or part of the process at lower temperatures. The present paper [...] Read more.
Improvement of the hot stamping process is important for reducing processing costs and improving the productivity and tensile properties of final components. One major approach to this has been to conduct all or part of the process at lower temperatures. The present paper reviews the state of the art of hot stamping techniques and their applications, considering the following aspects: (1) conventional hot stamping and its advanced developments; (2) warm stamping approaches in which complete austenitisation is not attained during heating; (3) hot stamping with a lower forming temperature, i.e., low-temperature hot stamping (LTHS); (4) advanced medium-Mn steels with lower austenitisation temperatures and their applicability in LTHS. Prospects for the further development of LTHS technology and the work required to achieve this are discussed. Full article
(This article belongs to the Special Issue Advanced Manufacturing Technology in the Automotive Industry)
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