Automotive Industry Research Articles

La sostenibilidad como valor de marca en la publicidad automotriz de España

Introduction: Climate change and Corporate Social Responsibility (CSR) have driven companies, including the automotive industry, to embrace sustainability as a fundamental part of their communication strategy. Purpose: The main objective of this study is to analyze sustainability as a brand value in digital advertising in the Spanish automotive industry. Methodology: This research follows a triangular methodology combining interviews, surveys, and analysis of advertising content to explore how experts and consumers perceive this trend, considering their gender and age. Findings: The result of this work shows that sustainability is increasingly influencing purchasing decisions, but there is a disconnect between what advertising conveys and what users value. Brands still prioritize design and price over sustainability, having to progressively adjust their messaging to better reflect the ecological and social concerns that audiences have. Originality/value: The contribution focuses on two paths: firstly, to fill an academic gap in terms of studies focused on the specific communication actions carried out by the automotive sector in Spain, and secondly, to demonstrate that sustainability has not entered as a brand value that forces higher sales.

Application of gray relational analysis for optimizing stud welding parameters of IF 7114 steel for the automotive industry

In this study, the application of stud welding to IF 7114 steel sheets in the automotive industry using stainless steel and copper-plated steel studs with different diameters and welding voltages was investigated. The aim is to optimize welding parameters and investigate their effects on the mechanical properties of the weld zone. Taguchi optimization and gray relational analysis were used to identify the best welding parameters for tensile strength and torque resistance. Results showed that the highest tensile strength and torque resistance were achieved with a stainless steel M8 stud diameter and 150 V welding voltage, while the lowest values were observed with copper-plated steel M5 studs and 180 V voltage. Additionally, stainless steel studs consistently outperformed copper-plated steel in both tensile strength and torque resistance. The study concludes that stainless steel studs, particularly with an M8 diameter at 180 V, offer the most favorable welding performance.

Titanium Additive Manufacturing with Powder Bed Fusion: A Bibliometric Perspective

Titanium additive manufacturing using powder bed fusion technologies has seen notable growth since 2015, particularly in high-performance sectors such as aerospace, biomedical, and automotive industries. This study focuses on key areas like metallic powder manipulation, laser optimization, and process control, with selective laser melting emerging as the dominant technique over electron beam melting. Advancements in powder materials and laser systems have been crucial to improving the efficiency and quality of the process, particularly in enhancing microstructure and porosity control. The bibliometric analysis reveals significant global interest, driven mainly by collaborations among institutions in Germany, the United States, and China, where further international cooperation is required to scale titanium additive manufacturing. However, additional research is essential to address challenges in scalability, sustainability, and post-processing, thus expanding the applications of PBF technology across industries. In conclusion, titanium processing via powder bed fusion is poised to make substantial contributions to the future of manufacturing, provided current challenges are addressed through innovation and enhanced global collaboration.

Effect of Thermal Expansion Mismatch on Thermomechanical Behaviour of Compacted Graphite Iron

Compacted graphite iron (CGI) attracts significant attention in the automotive industry thanks to its suitable thermomechanical properties and cost-effectiveness. A primary fracture mechanism at the microscale for CGI involves interfacial damage and debonding between graphite inclusions and its metallic matrix, which can occur under high-temperature service conditions due to a mismatch in the coefficients of thermal expansion between these two phases. Such microscopic interfacial damage can initiate macroscopic fractures in cast-iron components subjected to thermal loading. While this phenomenon was studied in various composites, there remains a lack of detailed information for CGI, especially related to the complex morphology of its graphite inclusions. This study investigates the influence of graphite morphology and type of matrix on the thermomechanical performance of CGI at high temperatures. A set of three-dimensional finite-element models were developed in the form of unit cells with a single graphite inclusion embedded within a cubic domain of the metallic matrix. Elastoplastic behaviour was assumed for both phases in the numerical simulations. The study is focused on the response of the constituents in CGI to pure thermal loading in order to explore the relationship between graphite morphology and fracture mechanisms. The findings aim to enhance understanding of how graphite morphology affects the behaviours of CGI under high-temperature conditions.

Effect of Surface Pretreatments on the Formation of Zr‐Based Conversion Layers on Zn–Al–Mg Alloy‐Coated Steel

ABSTRACTZr‐based conversion coatings represent an environmentally conscious alternative to traditional phosphating and chromating in the automotive industry. In this study, we employ XPS and LEIS to investigate the formation of Zr‐conversion layers on Zn–Mg–Al alloy after alkaline and acidic model pretreatments. On alkaline pretreated surfaces, a Zr‐oxide/oxyfluoride layer and an underlying Mg–Al–fluoride layer are formed, whereas acidic pretreatment results in only an oxidic layer. The thickness of the Zr‐layer depends on pretreatment pH and immersion time. Acidic treatment achieves an approximately 23 nm‐thick Zr‐oxide/oxyfluoride layer after 1 min, while prolonged treatment increases the thickness of the oxidic layer for strong alkaline and acidic conditions. Mild alkaline pretreatments, however, do not benefit from extended immersion. F‐induced corrosion pits are observed after mild alkaline treatment. The strong alkaline pretreatment proved to be the most efficient in creating a double‐layered Zr‐conversion coating with increased oxidic layer thickness over time.

Automation and the Importance of Reskilling Workers: A Case Study in the Automotive Industry

Rapid technological developments, especially the spread of automation and artificial intelligence (AI), have been transforming the world of work, raising some concerns about the future of employment. Automation presents both opportunities and challenges for the labor market. While we can expect productivity to grow with automation, and with-it economic growth, the fear of job loss linked to automation is also present. This paper aims to study the impact of automation on employment, with a special focus on the automotive industry, which stands out as one of the sectors most affected by automation. A second objective is to examine the reskilling procedures implemented by companies in this context, with a view to identifying effective strategies that bring benefits to both the employer and the workforce. To analyze the implications of automation in the automotive industry and the strategies adopted by companies to face these implications, we carried out an exploratory case study, using interviews, with the participation of four companies located in the districts of Minho, in the North of Portugal. The results show that, considering the impact of automation on employment, there is no negative impact since the destruction of some jobs was compensated by the creation of new ones. As for the reskilling procedures implemented by companies, results indicate that reskilling and upskilling are important strategies to prepare workers to transition to new jobs and tasks. Automation has been present in the automotive sector for many years and it has been gaining greater relevance over time. Businesses gain from several benefits provided by automation, including improved value for money, increased productivity, and increased worker safety. At the same time, they also face some challenges, such as high investment costs and workers' apprehension about transforming workplaces. Nonetheless, the investment pays off since companies invest heavily in reskilling their employees, and thus have a more qualified workforce that is prepared for any change that may arise. This paper contributes to a deeper understanding of the implications of automation in the labour market in the automotive sector and highlights the importance of workforce reskilling for the sustainability of companies. These findings are relevant for both employers and employees.

Fatigue Crack Growth Behavior of Additively Manufactured Ti Metal Matrix Composite with TiB Particles

Fatigue crack growth behavior of additively manufactured Ti metal matrix composite with TiB particles at room temperature was studied using a compact tension specimen and at the stress ratio of 0.1 (R = 0.1). The composite studied in this work was manufactured with a unique additive technique called plasma transferred arc solid free-form fabrication, which was designed to manufacture low-cost near-net-shaped components for aerospace and automotive industries. The fatigue crack growth rate experiments were carried perpendicular and parallel to the additive material build, aiming to find any fatigue anisotropies at room temperature. The findings reveal that additively manufactured Ti-TiB composite shows isotropic fatigue properties with respect to fatigue crack growth. Furthermore, the fatigue crack growth mechanisms in this additive composite material were identified as void nucleation/coalescence and the bypassing of particles and matrix, depending on the interparticle distance.

Leader Emotional Capital Matters in The Automotive Manufacturing Industry

The ability of an organisation to adapt to constant change determines its long-term viability. Organisations that understand the value of excellent leadership in organisational performance will see growth and sustainable profitability. This research focused on the automotive industry in Isipingo, Durban, KwaZulu-Natal, South Africa. To thrive and remain competitive, the automotive sector must adapt to changing conditions, be efficient, and respond rapidly to external forces. Managers are frequently challenged with balancing the frustrations of different interest groups within the sector; becoming skilled and successful leaders; and steering the organisation in the appropriate direction. The emotional competency of employees is a valuable resource designated as emotional capital. The purpose of this study was to investigate whether the emotions of leadership influence employee performance in this Industry Therefore, the research question entailed, what is the role of leaders' emotions? Analysis of extant literature was related to aspects that impact leaders’ emotional capability. The main variables included emotional capital, leadership, emotions, and employee performance. This study was based on a quantitative approach. Primary data was collected through a survey which was analysed using Spearman’s rho correlation. The results highlighted how a leader's emotions affect employees and demonstrated a substantial association between employee performance and the leader's overall emotional state. It was determined that a leader's emotions can have both beneficial and negative effects on employee performance. The recommendations offered useful advice on how to choose tactics that would yield appropriate results for the organisation to be sustainable.

Study on the Sound Absorption Characteristics and Noise Reduction Mechanism of Coconut-Shell-Activated Carbon Particles and Coconut Fiber Composite Biomass Sound-Absorption Materials

Abstract Sound absorbing materials are widely used in the field of automotive industry. Biomass materials are abundant in nature, and some biomass has natural sound absorption and noise reduction properties. Biomass sound absorption material is green and pollution-free, and has obvious noise reduction effect on middle and high frequency noise, large specific surface area, light weight, and strong sound absorption effect. In order to analyze the sound absorption and physical properties of biomass sound absorbing materials, the noise reduction performance of the different structure of biomass sound absorbing materials were analyzed. In this paper, the biomass sound absorbing materials coconut fiber and coconut shell activated carbon particles were used to make samples. Coconut shell activated carbon sound absorption material (CSAC) was made. The cylindrical holes was made and filled with coconut fiber materials to form composite sound absorbing materials (CSAC-F). The acoustic performance of impedance tube was tested based on the acoustic absorption coefficient, and the physical performance was studied by means of Scanning Electron Microscope (SEM), Brunauer, Emmett and Teller (BET), X-ray diffraction (XRD), Fourier Transform Infrared Spectrometer (FTIR), Thermogravimetric (TGA) and other detection methods. In contrast, the sound absorption effect of CSAC-F was better in the middle and low frequency range. The microstructure of the material was analyzed and the mechanism of noise reduction was studied. This research will provide a new way for the research and development of sound absorbing materials in the automotive industry, and biomass sound absorbing materials have potential applications in the noise absorption and vibration control of automotive interior.

THE IMPORTANCE OF ROOT CAUSES IN SOLVING PROBLEMS IN THE AUTOMOTIVE INDUSTRY

A key element of any quality management system is continuous improvement and a systematic approach to managing non-conformances. The aim of this paper is to use selected statistical methods and quality control techniques to present a way in which an organisation can achieve quality improvement. The 8D methodology was used to solve the observed front grid problem on the bumper of a Porsche Cayenne using a structured eight-step Plan-Do-Check-Act (PDCA) approach to problem solving. As this was an important customer originating from Dubai, it was imperative to immediately start solving the issue that arose with the ACC grid on the front bumper, the problem identified was an existing cut-out in the radar grid. Using the 8D methodology and supporting tools such as the Ishikawa diagram or 5Why, the root cause of the problem was identified and permanent corrective actions were planned and implemented as recommended in the 8D report to reduce the likelihood of the problem recurring and increase customer satisfaction.

Laser Sintering of Metal Powders: Failure Analysis and Implementation of Solutions for Aluminium and Stainless Steel Parts

Abstract In this research, the failures and possible solutions of direct metal laser sintering (DMLS) have been investigated, with the aim of presenting an overview of the current state of science and possible technical solutions to the various challenges and potential solutions. DMLS technology allows to produce high density parts and has proven to be suitable for the cost-effective production of both mass-produced and individual parts in the automotive, aerospace, medical and hydrogen technology industries. This study reveals the fundamental principles, potential benefits, and limitations of metal 3D printing. The defects are categorized into those related to raw materials and those caused by the manufacturing process. The properties of the parts fabricated by this method are mainly depending on the quality of the raw material and the intensity of the laser beam. Clusters of raw materials have a negative impact on the whole manufacturing process, requiring their investigation and avoidance. Another critical defect identified is the significant internal stress generated during the manufacturing process. Various methods are developed to quantify and mitigate these internal stresses. This study provides a detailed analysis of these defects and their impacts, along with a review of literature-based solutions. Among the evaluated and implemented solutions, emphasis is placed on the effects of preheating the build plate and post-process heat treatment. Future objectives and research directions are proposed, presenting and assessing alternative solutions such as Vibratory Stress Relief (VSR) and Thermo-Vibratory Stress Relief (TVSR), which combine heat treatment with vibration. In the scope of the research, the process by which the most common failures occur, and their potential outcomes was reviewed. Special attention was given to deformation caused by internal stress and the possibilities for its mitigation. The feasibility of applying a new approach was investigated, and future research objectives were outlined. SEM imaging was employed to conduct and analyse the grain size of stainless-steel raw material, and agglomerates were observed in the post-print recycled powder.

The Influence of the Amount of Technological Waste on the Performance Properties of Fibrous Polymer Composites

The objective of the experimental analysis was to assess the impact of the reuse of technological waste (recyclate) on the selected performance properties of the fibrous polymer composite used to produce components for the automotive industry by injection molding technology. Polyphthalamide (PPA), which belongs to a group of high-tech polymers, was chosen as the analyzed material. In accordance with the set goals, the rheological, mechanical, and structural properties of the material were evaluated using ANOVA analysis in the experimental part of the work, depending on the mass ratio of the recycled material added to the virgin material. The influence of the proportion of recycled material on the lifetime of moldings by the method of their exposure at an elevated temperature for a defined time was also assessed. During the research, it was found that at a concentration of up to 40 wt. % of recyclate, its mechanical properties do not change significantly. At a concentration of 50 wt. %, there is a rapid decrease in mechanical properties. In the long term, it can also be said that the addition of recyclate significantly affects the service life of the components. No significant changes in morphology were observed during the analysis of structural properties.

Quantitative Analysis of Predictors of Acoustic Materials for Noise Reduction as Sustainable Strategies for Materials in the Automotive Industry

This study proposes a qualitative analysis for identifying the best predictors for ensuring passive noise control, aiming to achieve superior acoustic comfort in transportation systems. The study is based on real experimental data, collected through acoustic measurements performed by the authors on materials from six different classes and employs a multidisciplinary approach, including Mann–Whitney U tests, Kruskal–Wallis analysis with Dunn’s post hoc multiple comparisons and multilinear regression. This research presents an analysis and evaluation of how the physical properties of various materials influence acoustic comfort, acoustic absorption class and absorption class performance and proposes quantitative models for material selection to address sustainable strategies in the automotive industry. The results highlight significant differences between material categories in terms of acoustic absorption properties and demonstrate the importance of rigorous material selection in vehicle design to enhance acoustic comfort. Additionally, the research contributes to the development of predictive models that estimate acoustic performance based on the physical properties of materials, providing a basis for optimizing material selection in the design phase.

The Machinability of Different Albromet W130 Plates Thicknesses by WEDM to the Required Surface Roughness Value

Wire Electrical Discharge Machining (WEDM) technology represents an unconventional but vital manufacturing technology in many different industrial branches. The automotive industry and its many significant requirements bring the need to manufacture inserts and mould segments for plastic injections from Albromet W130 material, with a required roughness, Ra, from 4.5 to 5 µm so that subsequent profile etching can be eliminated. A planned experiment of 60 rounds was carried out to discover the optimal machining parameters, namely, the pulse-off time, gap voltage, discharge current, pulse-on time, and wire speed in order for the thickness of 10 to 100 mm (after 10 mm) to demonstrate the required roughness. The goal was to evaluate the surface roughness, maximise the cutting speed, and manufacture it without surface or subsurface defects. The evaluation of the planned experiment led to the establishment of optimised WEDM machining parameters with which thicknesses of 10–100 mm will always be produced with the required roughness, Ra, from 4.5 to 5 µm and with the highest possible cutting speed. It was also proven that the machining does not lead to surface or subsurface defects, and thus, the service life of the manufactured parts will not be affected.

Parameter Optimization for Dissimilar Aluminum Alloys Joined Using Friction Stir Additive Manufacturing: A Screening Study

ABSTRACTDue to the requirement for better strength‐to‐weight ratios, the utilisation of aluminum alloys is rapidly expanding. Lightweight components are of utmost importance in most industries, particularly in transportation, aviation, maritime, automotive, and other industries. These lightweight engineering materials are hard to be joined utilising traditional fusion joining techniques, necessitating the development of alternative joining techniques. The novel friction‐stir additive manufacturing (FSAM) technique, based on the concept of friction stir welding (FSW), can be used to combine aluminum alloys additively in their solid state. This work examines the effects of several process parameters (tool rotational speed, tool tilt angle, and tool transverse speed) on tensile strength and hardness using a 3‐factor L9 Taguchi designed experiment. Three cases were explored, one were AL 6061 was welded to AL 7075, one where AL 7075 was welded to AL 6061, and one where the data were mixed to get an “average” effect representative of large additively manufactured parts. A detailed ANOVA (including both main effects and interactions analyses) provided clear guidance on the optimization of the parameters for several objectives. This work will contribute to the development and wider use of FSAM in both industrial and academic research settings by providing a useful dataset and clear parameter selection guidance. The results of this research indicate that the FSAM methodology could be utilized to fabricate large defect‐free structures, which can be a suitable replacement for the traditional Al6061 material used in automotive and aerospace sectors.

The adoption of talent retention strategies in Industry 4.0 automotive organisations: Employees’ perspective

Orientation: As the second largest employer in South Africa (SA), the automotive industry has a vital role to play in addressing global talent retention challenges in the era of Industry 4.0.Research purpose: The aim of this study was to identify talent retention strategies within automotive organisations in SA within the context of Industry 4.0.Motivation for the study: The United Nations identified 17 goals it needs to address which require the automotive industry to adopt effective talent retention strategies.Research approach/design and method: This article reports on the quantitative component of a mixed-method study conducted in the South African automotive industry where data were collected from human resource (HR) and operational employees in automotive organisations through convenience sampling.Main findings: The talent retention strategies need to be more effective to retain Industry 4.0 talent as a ‘one-size-fits-all’ approach is not ideal.Practical/managerial implications: Addressing the sustainable development goals in Industry 4.0 will require the upskilling and reskilling of current employees by means of target interventions. Ensuring the development and maintenance of a talent pool is formidable for ensuring talent sustainability in the automotive industry.Contribution/value-add: This study is a prima facie case that focusses on talent retention strategies in the context of automotive organisations in South Africa and, specifically, HR and operational employees. Also, based on the databases searched, little research was found that focussed on Industry 4.0 talent retention strategies from the perspective of the automotive industry.

Parameters influence on mechanical properties of resistance spot welding: AISI304L/AISI1005

AbstractWelding dissimilar metals by resistance spot welding offers several advantages, including lighter weight and better mechanical properties for the shipping, aerospace, and automotive industries. The resistance spot welding parameters effects (welding current, squeeze time, welding time, and hold time) on the welding results of AISI 1005 and AISI 304L were investigated in the present research. The joints' tensile shear force, microhardness, and microstructure were examined. The Taguchi design of experiments approach was utilized to analyze the tensile shear force results statistically. A welding current of 7 kA, welding time of 1.4 s, squeeze time of 1.2 s, and hold time of 0.8 s resulted in an optimum tensile shear force of 6.194 kN. Additionally, the nugget zone demonstrated a higher hardness compared to the base metal and heat-affected zones.

FRICTION STIR PROCESSED MAGNESIUM MATRIX SURFACE COMPOSITES: A COMPREHENSIVE REVIEW

Abstract Nowadays modern materials are tailored using different manufacturing techniques. Usually, material surface is modified by even distribution of reinforcement particles/ fibres up to a certain depth. The developed surface metal matrix composites (MMCs) exhibit superior metallurgical, mechanical and electrochemical properties in contrast to base materials. These surface MMCs have potential applications in biomedical, automotive, aerospace and power industries. Many techniques have been used to develop these surface MMCs, however, the friction stir processing (FSP) has gained wide popularity. This review paper summarizes the effects of different FSP parameters on the metallurgical, mechanical and electrochemical properties of developed surface composites. Furthermore, the effects of secondary phase particles on the Magnesium-matrix surface composites are also comprehensively discussed.

Exploring the synergistic effects of graphene on the mechanical and vibrational response of kenaf/pineapple fiber‐reinforced hybrid composites

AbstractThe automotive, aerospace, and sports industries are increasingly utilizing hybrid composites made from natural fiber reinforcements. This study evaluated the performance of a composite made from kenaf and pineapple fibers, manufactured using the compression molding process, with graphene nanoparticles added at varying weight concentrations of 0.5, 1.0, 1.5, and 2.0 wt%. Results showed that adding 0.5 wt% graphene increased the tensile, flexural, and impact strength of hybrid composite by 133.75%, 90.24%, and 25.67%, respectively. Microstructural analysis revealed that graphene integration has enhanced the interfacial bond between the fiber and the matrix, creating resin‐rich areas. Furthermore, the free vibrational analysis indicated that graphene‐infused composites exhibited higher natural frequencies, improving their energy‐absorbing capabilities. Water absorption tests demonstrated that the inclusion of graphene reduced water penetration by improving interfacial bonding, minimizing voids, and decreasing surface energy, which limited water pathways in the composite. Furthermore, the composites with 0.5 wt% graphene showed a contact angle of 80.8°, indicating lower hydrophilicity compared to neat composites, which had a contact angle of 70.7°. This research emphasizes the advantages of hybrid composite materials derived from kenaf and pineapple fibers, specifically for applications in vehicle interiors and construction, including wall panels and separators.Highlights Hybrid composite was prepared using the compression molding process. Adding 0.5 wt% graphene improved the mechanical properties of composites. Hybrid composites with lower wt% graphene had higher natural frequencies. The composites with 0.5 wt% graphene had better water absorption properties.

Design and validation of fixation points of polymeric components for the automotive industry

ABSTRACT The incorporation of polymeric materials in car structure components plays a key role in the automotive sector, enabling the production of more efficient and ecological vehicles. Among the many options to fix these components, there are clips and snap-fits, which not only facilitate assembly and disassembly, but also contribute to reduce the total mass of the car. This work aims to design and validate these fixation points of polymeric components using the Design Science Research (DSR) methodology. The work resulted from the need for a more rigorous control involving some internal standardized fixation points, namely interior trim parts. Experimental tests were carried out according to the specifications of the automotive brand, including the strength of the fixation points, to enable incorporation as standard components. Using the Finite Element Method (FEM), static simulations were performed in the Abaqus® software, where the conditions of the physical tests were replicated to correlate both tests and validate the numerical approach. Improvement of the fixation points was next undertaken, by making changes in the areas that were identified as critical. The improved fixation points were able to meet the specifications of the company and were proposed as new geometry for standard interior trim parts.