This paper studied iron-ductile metals with incubation/spheroidization treatment and adjustable graphite ball density. Using analytical methods like Scanning Electron Microscopy (SEM), ultrasonic thermal melt loss weight, the paper systematically studied the effects of different nodular graphite densities on the hot melt loss properties of iron-ductile metals. The results show that with the increase of ductile density, the weight of hot melt loss of iron-ductile metal gradually decreases, the molten aluminum corrosion resistance of iron-ductile metal is significantly improved compared with that of H13 steel. After the iron-ductile metal immersion thermal melting experiment, the thickness of the Fe-Al reaction product layer is inversely proportional to the ductile density, the graphite spheres with small spacing and large specific surface area hinder the contact between the molten aluminum and the matrix, diffusion of molten aluminum, thereby inhibiting the corrosion of the matrix by molten aluminum. Iron-ductile metals exhibit better resistance to aluminum melt corrosion.

The continuous improvement of input power and device integration of high-power LED automotive lighting enables the chip junction temperature increase rapidly in a short period of time, reduces its service life and luminous efficiency. Thus improving heat dissipation of LED automotive lighting is a major issue of the present studies. A micro-arc oxidation ceramic coating with a micro-porous structure was prepared on the surface of the aluminum alloy radiator by using micro-arc oxidation surface treatment technology to increase its heat dissipation surface area, the chimney effect produced by the porous structure of the ceramic membrane was used to enhance the convection of heat. This paper utilized ANSYS software to simulate the heat dissipation performance of micro-arc oxidation ceramic coating of high-power LED aluminum alloy radiator, and studied the effect of micro-arc oxidation ceramic coating thickness and porosity on the heat dissipation performance of the radiator. The results show that, when the thickness of the ceramic coating is 28 μm and the porosity is 50.26%, the LED aluminum alloy radiator has the highest thermal conductivity, the smallest thermal resistance value, the best heat dissipation performance.

For the suspected local flexion injury found during vehicle development, the local flexion was confirmed through comparison of critical flexion stress calculations and measurement of normal deformation, identifying the potential risk of local flexion on durability performance. Through stress measurement, the S-N curve at the notch was modified using the Haywood model. Based on the fatigue damage accumulation model that considers loading sequence and interaction, and the dynamic residual S-N curve, the residual lifespan of the component was calculated, and compared with the experimentally measured residual lifespan to verify the feasibility of the method. Based on the above residual lifespan estimation method, a durability target modification method was proposed, pointing out the shortcomings of this method and engineering solutions.

Through the Design Of Experiment (DOE), the simulation model of glass flush and lifting torque, the key quality characteristics of Flush Door system, was established, and the significant factors affecting response variables were analysed, and the system robustness before and after tolerance optimization was simulated by Monte Carlo. The Simulation results show that the determination coefficient (R²) of glass flush and lifting torque are 0.968 6 and 0.963 9 respectively, which indicates the models agree well with experimental data. After tolerance optimization, the product out-of-tolerance rates of glass flush and lifting torque are reduced from 0.62% and 1.71% to 0 respectively. At the same time, the redistribution of the tolerance zones has reduced the product out-of-tolerance rates by 0.60% and 1.67% respectively, significantly improving the robustness of the system tolerance design.

In order to improve the visual, auditory, olfactory, tactile and other subjective feelings brought by the passenger car seal strip, this paper, through the study and discussion of the automotive seal strip extrusion process, clarified the general review content of the seal strip extrusion process in the trial production stage, so that the external seal strip can follow a unified evaluation standards in the design and manufacturing process. The paper systematically introduced raw materials, classification, structure and properties of seal strips as well as the key points of process control in the process of extrusion, so as to meet the following requirements including seal strip Product Verification(PV) tests, functional requirements for vehicle sealing, vehicle appearance and exterior trims.

In order to analyze the cause for the difficulty of gear engagement for passenger car transmission, harmonic analysis was conducted on the friction cone of the driving and driven gear synchronizer of two manual transmissions returned from users, it was found that the high-order harmonic amplitude of the synchronizer friction cone was abnormal, which was consistent with the user’s hand feel. Therefore, the harmonic amplitude of the synchronizer friction cone of the driving and driven gear parts must be controlled in the manufacturing process. After several bench tests, it was concluded that the each order harmonic amplitude of the friction cone of the synchronous gear parts of the manual transmission was in line with the range, which was added to the monitoring plan for manufacturing process quality control, and no similar quality problems occurred after that.

This paper analyzed and studied the color difference control methods in the development of new color of automobile body, the key points and difficulties of color difference control under special structure. According to the characteristics of different colors, it requires different color deviation management bias and standards. Under the special structure of the body, the optimal color difference management angle and standards are obtained according to the analysis of different visual angles.

This paper refined, analyzed and studied the important and difficult issues in the color development and application of automotive body color double base process. At the initial stage of introduction, the paper compared and analyzed the difference between the double base process of color paint and the ordinary single base process, then analyzed the characteristics of a typical case of the double base process of matching color paint (red flame and red color), and determined the key points of the biotechnical test of the double base process of color paint and the difficult issues that will appear in the application stage, which mainly including 3 difficult issues, i.e. the B column color difference, paint repair difficulties and color matching, then measures were given for different stages of color development. This paper sorted out the application points, difficulties and effective countermeasures of the development of double base process of color paint.

Since collaborative robot has the features of simple operation, flexibility, convenience, safety and reliability as well as easy integration with other advanced technologies, this paper therefore proposed creatively the design program of using cooperative robot to install expansion blocks in the welding shop. Based on JAKA collaborative robot, through the design and verification of the cooperative robot’s gripper, the collaborative robot was selected according to the load, offset distance and working radius. Worker and collaborative robot work together on the expansion fixture of expansion blocks, cost reduction and efficiency increase were achieved. At the same time, it also provided ideas and references for the installation of other small parts.

Large capacity body storage areas play key roles in the production system of the automotive paint workshop. This paper introduced the function, form and performance of the paint workshop, discussed the advantages of stereoscopic warehouse compared with plan warehouse. By comparing the structure and operation mode, the Rail Guided Vehicle (RGV) stereoscopic warehouse, advantages over the stacker-type stereoscopic warehouse were analyzed. Based on these advantages, the application of RGV type stereoscopic warehouse effectively improves the production efficiency and flexibility of paint workshop.

The corrosion behavior of hot rolled steel plate (SPHC) under enhanced corrosion test condition of automobile was studied. The morphology, composition and phase of corroded surface of SPHC steel after 7, 11 and 19 days of test were analyzed by Scanning Electron Microscopy (SEM), Energy Dispersive Spectrometer (EDS) and X-Ray Diffractometer (XRD). The results show that the corrosion rate of SPHC presents a nonlinear change with the test time under the enhanced corrosion test condition of automobile. When the test was from 3 to 7 days, the corrosion rate increased sharply first, and Fe₂O₃ was formed on the surface, which accelerated the initial corrosion. When the test reached the 11th day, the corrosion rate began to drop to a low point, Fe₂O₃ and protective α-FeOOH were formed on the etched surface. At this time, the rust layer was relatively dense, which enhanced the corrosion resistance of SPHC. When the test reached the 14th days, the corrosion rate began to show an upward trend, the corrosion products such as Fe₂O₃, trace amounts of α-FeOOH and Fe₃O₄ were generated on the surface of SPHC. At this time, the rust layer was peeling off and the corrosion was more serious.

The wire harness tape made of glue & base is the major part of the wire harness. In order to learn about the performance of Volatile Organic Compounds (VOC) on different tape glues, the automobile standards of odor grade evaluation & VOC were applied on the experiment, tapes with different kinds of glues were tested and compared. The test results show that the acrylic ester glue tape is obviously better than the rubber glue one in the VOC content, meanwhile because of other superior performance, it provides guideline for the development of wiring harness tapes.