To accumulate experience in the design and manufacturing of lightweight vehicle body connection technologies and enhance the quality of vehicle body mechanical connection processes, this paper summarizes and analyzes lightweight vehicle body mechanical connection technologies such as self-piercing riveting, rivetless connection, hot-melt self-tapping riveting, bolt connection, pull riveting and pressing riveting, and elaborates in detail the process principles, process characteristics, quality control methods and innovative process schemes of each process.

Improper handing of the power batteries of New Vnergy vehicle (NEV) throughout the life cycle will cause environment pollution and waste of resources. This paper discusses the current status of environmental protection technology for NEV power battery in terms of current materials selection, recovery systems and policy support. It also explores the development direction of power battery environmental protection technology from 3 aspects of innovation of materials, upgrading of recovery systems and follow-up of support policies.

This paper analyzes and summarizes the impact of China’s natural environment, industrial atmospheric environment and road conditions on the occurrence and acceleration of corrosion in automotive metal materials. The results show that temperature, relative humidity, soil acidity and alkalinity, salt spray in coastal areas, road deicing salt, and industrial atmospheric pollutants are key factors that induce and accelerate the corrosion of vehicle bodies and components. Therefore, in automotive development, rational anti-corrosion design should be made based on these key factors, and corresponding corrosion verification methods should be established to improve the compatibility between the anti-corrosion performance of vehicles and their actual corrosion life, thereby reducing quality issues and cost waste telated to anti-corrosion.

To improve the service life of automotive brake pedals, this paper investigates the impact of different factors affecting the fatigue failure of automotive pedal components, applies the Fault Tree Analysis (FTA) method to solve the structural importance of components through the minimal cutset. The frndings indicates that material and load are the primary causes affecting the life of brake pedal components, with stress concentration being a seeondary cause. Taking a heavy truck brake pedal Finite Element(FE) model as an example, the finite element software Hypermesh and fatigue software nCode are used for predication and analysis, and the stiffness test experiment of the pedal is carried out to verify the rationality of the model.

In order to explore the influence of bio-based plasticizers and leather structure on the properties of Polyvinyl Chloride (PVC) leather materials for automobiles, system test and performance test are conducted to find that using suitable eco-friendly bio-based plasticizers for automotive interior PVC leather can meet requirements such as -10 ℃ and 30 000 times folding durability for automotive interior PVC leather materials. PVC leather using environmentally friendly bio-based plasticizers instead of petroleum-based plasticizers has green ecological and skin-friendly comfort properties, and emission of volatile organic compound and aldehyde-ketone substances is significantly lower than that of ordinary PVC leather for automotive interior, which has remarkable low-volatile and environmental protection advantages.

In recent years, thixomolding technology has imparted thriving vigor to the magnesium alloy industry. This paper reviews the development and application prospects of thixomolding technology for magnesium alloys. Firstly, the principle and distinctive advantages of thyroiodin process for magnesium alloys are described in detail. Subsequently, the historical development of magnesium thixomolding machines is summarized, highlighting that China is gradually be coming an innovation leader in the field of large-scale equipment teehnology. Furthermore, this paper analyzes the latest advancements in research on microstructure and properties of magnesium materials utilizing thixomolding technology, and points out that this technology can fully exploit the performance potential of magnesium alloy and effectively reduce casting defects. Beyond the commonly used Mg-Al system, novel semi-solid magnesium alloys are also being researched and developed. Concurrently, magnesium matrix composites by thixomolding have garnered attention due to short process and high performance. Thixomolding technology for magnesium alloys has been applied in consumer electronics, transportation tools, etc., and is gradually expanded to the production of large structural parts, especially demonstrating strong application potential in the field of new energy vehicles.

Physical Vapor Deposition (PVD) is an important means of metallization of plastic surface. This paper summarizes the concept and characteristics of PVD technology such as evaporative plating, sputtering plating and ion plating. It also elaborates production process of evaporation and sputtering plating, and compares the advantages and disadvantages with those of plastic plating. Moreover, the application of PVD technology in automotive interior parts and related test and verification projects are introduced and the development trend of PVD is summarized and prospected.

This paper focuses on the research, development, application, industrial layout and future trends of hot-formed dual-phase steel ring technology in automotive manufacturing. Initially, the paper provides an overview of the current status of key technologies related to hot-formed dual-phase steel rings, covering material selection and development, application of laser welding technology and optimization of stamping processes. The paper subsequently analyzes the industrial layout of hot-formed dual-phase steel rings, and emphasize the importance of core technological systems in the industrialization process. Finally, the future development direction of this technology is prospected, highlighting the advancements in high performance, lightweight, environmentally friendly and intelligent manufacturing.

This study systematically investigates the pressure-bearing capacity and failure mechanism of air suspension reservoirs through numerical simulation, burst testing, and theoretical calculation. Based on nonlinear material constitutive relations, numerical simulations reveal that when the cylinder wall thickness increases to 2.3 mm, the maximum equivalent plastic strain reaches 6%, demonstrating sufficient strength to withstand the design pressure of 6 MPa. Burst tests show the actual pressure-bearing of the 2.3 mm thick reservoir reaches 7.29 MPa, with failure consistently occurring at the nozzle-joint area, correlating perfectly with high-stress zones identified in simulations. Fracture surfaces exhibit continuous tearing morphology, confirming typical ductile fracture characteristics. Comparative theoretical calculation indicates the mean diameter formula achieves merely 2.2% deviation from experimental results, significantly outperforming the Faupel formula, thus validating its superiority for burst pressure prediction in thin-walled reservoirs.

Through the comparative study of different technical routes of aluminum alloy automotive body, this paper proposed the lightweight body solution of “profile frame + cover part” steel-aluminum hybrid heavy truck. Based on the body structure, the material selection, the joining process comparison study and solution formulation were completed, and the CAE software was used to simulate and analyze the modality, stiffness, fatigue and collision performance of the body and all performance indicators meet the product requirements. Compared with the original steel body, the steel and aluminum hybrid heavy duty truck body is 81.5 kg lighter (a decrease of 22.4%), which provides a reference for the subsequent lightweight design and manufacture of heavy duty truck body.