Packaging reliability of control chips, which serve as the central components of Electronic Control Units (ECUs), directly affects the safety performance of automobiles. This paper systematically investigates the mechanism of delamination failure of two mainstream ECU architectures namely Microcontroller Unit (MCU) and System-on-Chip (SoC) based on composite load characteristics of mechanical vibration and temperature shock under typical conditions of automobile. The research results indicate that under multi-load coupling, interface bonding strength attenuation and thermal mismatching of materials caused by performance degradation of key positions like die attach interface, wire bond interface and underfill packing layer are the primary factors inducing delamination failure. This paper compares the application of three finite element analysis techniques—Virtual Crack Closure Technique (VCCT), J-integral, and Cohesive Zone Model (CZM), which indicates that CZM has interface representational dominance under large deformation condition of nonlinear material, while J-integral is applicable to small deformation fracture zone of nonlinear material, and VCCT has advantages in computational efficiency in the analysis of linear elastic steady-state crack propagation.

By integrating flexible sensors into automotive seats, steering wheels, and powertrain components, it is possible to monitor the occupants’ physiological indicators (heart rate, respiration) and vehicle health status in real-time. This paper systematically reviews 2 major application scenarios of flexible sensors in intelligent vehicles: environmental perception (e.g., in-cabin gas monitoring) and human-machine interaction (e.g., haptic feedback, intelligent cockpit perception). It further analyzes 3 core technical routes of flexible pressure sensors: nanocomposite-based piezoresistive sensors, porous ionogel-based capacitive sensors, and polymer-based piezoelectric sensors. The study delves into signal transduction mechanisms for each technical route, providing theoretical support for constructing multi-modal perception networks in intelligent vehicles.

The innovation of flexible Organic Light-Emitting Diode (OLED) technology in the automotive sector focuses on systematic breakthroughs in performance enhancement and form adaptability. This paper analyzes the topic from 3 perspectives: materials science, device engineering, and scenario-based applications. The content includes the multi-color emission mechanism of OLEDs, core packaging processes of flexible OLED devices, and the selection of flexible substrates. Automotive applications are explored, including transparent A-pillars, central control displays, and interactive tail lights. Additionally, 3 main technological challenges and future development trends are summarized.

Starting from the functions of flexible photoelectric materials, this paper introduces their advantages in lightweight and spatial layout in automobiles, summarizes different classifications and structural characteristics of flexible photoelectric materials, and introduces the applications and progress of flexible printed circuit boards, organic light emitting diodes, and intelligent color changing materials in automotive sensors, vehicle lighting, vehicle display screens, and other fields. Finally, the future development trends of various types of flexible photoelectric materials in automotive applications are discussed respectively.

Bimetallic compound casting combines 2 metal materials with different compositions and properties into a single integral casting, meeting the performance requirements at different parts of the components that are difficult to achieve with a single metal material, and achieving automotive lightweight. This paper reviews liquid-solid bimetallic compound casting process, analyzes the bonding mechanisms and formation conditions of bimetallic interfaces, and summarizes the interface microstructure and performance control technology such as surface treatment, insert preheating, adding interlayers and application of physical fields, it also presents the typical applications and manufacturing processes of aluminum/cast iron, aluminum/steel, aluminum/magnesium and steel/cast iron bimetallic compound casting in automotive lightweight manufacturing. The paper finally presents the research direction and development prospect of bimetallic compound casting, providing a valuable reference for the research and its application in automotive manufacturing.

To stabilize mechanical property of automotive structural components made of 7-series extruded aluminum alloy, and enhance the finished product rate for subsequent deep processing, this study uses the 7108 extruded aluminum alloy profile of the structural part for new energy vehicles as the test material, conducts three stages of processing, including natural aging, pre-aging and pre-aging + artificial aging, and confirms the influence of the optimal pre-aging system and pre-aging of 7108 extruded aluminum alloy profile of automotive structural part on the mechanical properties and intergranular corrosion resistance of subsequent artificial aging. The results indicate that pre-aging can effectively control the increase in mechanical properties of 7108 aluminum alloy profiles under natural conditions, thereby improving the machinability of the product.

To address the issue of inaccurate test results caused by unstable clamping and leakage in the airtightness testing tooling for electric vehicle battery box, a force analysis is conducted on the fixture, and a self-locking verification of the clamping mechanism is performed. This proves that sufficient and stable clamping is the necessary and sufficient condition for the fixture to achieve sealing and thereby conduct accurate testing. Based on this finding, this paper proposes an optimized fixture design. The verification resules shows that the design can significantly improve the fixture’s sealing performance and accuracy of airtightness testing.

For the car door dissimilar galvanized steel, this paper explores in the conditions without the use of prefabricated protruding point, by adjusting the laser welding power, welding speed, welding pendulum amplitude, to develop a sinusoidal pendulum based new laser welding process, to achieve first-stage welding of the dissimilar galvanized steel sheet. Meanwhile, the paper also explores the rule of influence of different process parameters on weld morphology and mechanical properties of welded joints in the process of oscillating laser welding, to provide theoretical basis and technical support for the development and application of new automotive laser welding process and cost optimization of production line scheme planning.

In order to reduce the influence of temperature field, welding residual stress, human factor, etc., on welding quality of structural welded parts, firstly, a three-dimensional model of structural welded parts is established to simulate and analyse welding temperature field, welding residual stress and welding deformation, subsequently, the influence of clamping condition, heat source pattern and welding parameters of structural welded parts on welding deformation and welding residual stress is investigated, simulation and test results are compared, thus identifying the cause of welding deformation and modification method. Finally, welding sequence and welding direction are used as design variables for welding sequence optimization with genetic algorithm, in which the least welding deformation sequence is obtained by simulation with the least welding residual deformation as optimization objective. On the basis of optimizing welding sequence, the clamping position, reverse deformation design method are simulated and optimized respectively, thereby obtaining the process design scheme and the optimal forming accuracy with the least welding deformation.

This paper investigates the microstructure, mechanical properties and elemental distribution of welded joints using the CMT Cycle Step process with AZ81 filler wire for AZ31B magnesium alloy extruded plates to develop new welding technologies for magnesium alloys. Comprehensive characterization is performed through optical microscopy, Vickers hardness tester, tensile testing machine, Scanning Electron Microscopy (SEM) and Energy-Dispersive X-ray Spectroscopy (EDS). The experimental results demonstrate that uniform and regular fish-scale patterns are formed on the weld surface. The weld zone primarily consists of α-Mg phase with discontinuous eutectic structures at grain boundaries. While Zn element distribution shows no significant concentration difference across the base metal, fusion zone, and weld zone, Al element exhibits markedly higher concentration in the weld region compared to the base material. The maximum hardness is observed in the weld zone, with a distinct softening phenomenon characterized by significant hardness reduction in the Heat-Affected Zone (HAZ). The tensile strength of the welded joint reaches levels comparable to the base material. Tensile fractures occur in the HAZ, presenting pure shear fracture surfaces with morphological features indicative of ductile fracture characteristics.