In order to solve the problem of the leakage of the flat tube of the all-aluminum low-temperature water tank in the thermal shock test, this article proposes 3 design adjustments, namely, widening the flat tube, changing the O-type collector tube and adding the spacer plate. Finite element analysis software Abaqus is used on the original design scheme and all-aluminum low-temperature water tank under 3 kinds of adjustment scheme for Finite Element Analysis (FEA) analysis, to get the maximum local stress of the flat tube at the leakage area and the maximum plastic strain and its distribution. Thermal shock bench tests are conducted using thermal shock life and the number and location of flat tube leaks as indicators. The results show that the thermal shock life is inversely proportional to the maximum local stress and plastic strain. The location of the leaking flat pipe of the test piece is consistent with the local stress and plastic strain distribution pattern, and the FEA simulation analysis is in good agreement with the test verification. Therefore, in order to extend the thermal shock life of the all-aluminum low temperature water tank, the program sequence is optimized as follows: use of O-type collector tubes, use of narrow flat tubes and use of double bulkheads.

In this research, DC56D+ZM steel plate and DC56D+Z steel plate with coating thickness of 0.7 mm are taken as the research objects. The feasibility and mechanism of Zn-Al-Mg coated steel plate to solve stamping cracking are verified by using friction testing machine for sheet metal forming and stretching ribs, sheet comprehensive forming testing machine, scanning electron microscope, and MTS nanoindentation testing machine. The results show that the surface friction coefficient of the Zn-Al-Mg coating is 25% lower than that of the pure zinc coating. The forming limit performance of Zn-Al-Mg coated steel plates is better than that of pure zinc coated steel plates. Due to the finer grain size and higher hardness of the Zn-Al-Mg coating, the coating has a lower and more stable surface friction coefficient, which can significantly improve the forming performance of the steel plate and effectively improve the stamping cracking problem of automobile parts.

Based on the characteristics of e-ink, flexible segment-code e-ink diaphragm is used to integrate with the trim strip of a vehicle, in order to explore the feasibility of integrating e-ink and interior parts, and the vehicle specification test is conducted. Environmental tests show that the e-ink diaphragm or module can withstand the high and low temperature range of -40~70 ℃, and the e-ink diaphragm will be damaged if the temperature exceeds 70 ℃. The alternating test in the temperature range of -30~85 ℃ is easy to cause the wrinkle or stratification of the multi-layer structure of the module. Therefore, the structure and material of e-ink cannot fully meet the automobile specification test, and further research is needed to identify the application potential of e-ink in automobile interior parts.

In response to the occurrence of defects such as shrinkage and porosity during the casting process, which lead to stress concentration under high load conditions, produce local high stress-strain zones and local yielding, resulting in reducing the service life of the parts. By using a combination of finite element simplified modeling and experimental analysis verification, the effects of the distance between micropores and the free surface, the distance between the pores, the porosity morphology and the distribution angles on the stress concentration in A356 cast aluminum alloys are systematically studied. The relationship between the influence of each defect feature on the stress-strain concentration is established, and the established relationship is verified by actual pores in the sample.

With the aluminum alloy door of passenger car as the research object, the laser wire filling welding process and welding quality of aluminum alloy sheet are studied through comprehensive application of simulation and process test. The optimal process parameters suitable for laser wire filling welding of aluminum alloy door are obtained by judging the forming quality and mechanical properties of the weld after welding. Using this parameter, the laser wire filling welding of the inner plate assembly of the aluminum door is prototyped and a better welding quality is achieved. The results show that for the laser wire filling lap welding of 5182 aluminum plate and 6016 aluminum plate with thickness of 1.5 mm, better weld forming quality and mechanical properties can be obtained with the following process parameters: 2 600 W laser power, 2.5 m/min welding speed and 7 m/min wire feeding speed, and can satisfy the welding quality requirements of the actual aluminum door inner plate assembly.

To get reliable forming process parameters for aluminum products, the inner panel of an automotive aluminum door is taken as the research object. Considering the structural characteristics of this product, the process modeling and analysis are initially performed using the AutoForm software to identify the risk areas of its forming defects. Subsequently, the blank size, binder force, and the resistance coefficient of the drawbead are adopted as the design variables for process optimization. The process optimization analysis is implemented through the Sigma module. After a cumulative total of 114 iterative operations, the optimal parameter combination that complies with the forming quality evaluation criteria is obtained. Production verification shows that the formed quality of the stamped parts is excellent according to the optimal parameter combination.

In order to explore the effect of annealing process on the properties and microstructure of 3003 aluminum alloy for lithium battery of new energy vehicle, the evolution characteristics of room temperature mechanical properties, hardness, cupping value, earing rate and microstructure of 3003 aluminum alloy for lithium battery of new energy vehicle after annealing at different temperatures (150 ~ 500 ℃) and holding for 3 h are studied by means of electronic universal testing machine, hardness tester, cupping test machine, forming test machine and optical microscope. The preferred experimental annealing process of 3003 aluminum alloy is determined. The results show that the best combination of mechanical properties, formability and microstructure of 3003 aluminum alloy is obtained when the annealing temperature is 400 ℃ and the holding time is 3 h. This annealing process is applied to the box-type annealing furnace on the production site for verification, which is in good agreement with the test results.

To solve the quality issues that rear quarter PVC residue interference with assembly shop installation, PVC material, nozzle temperature and robot application program are optimized as following. For PVC material, Relevant viscosity and yield value with the precondition of no influence to the tightness and appearance are increased; The nozzle temperature is reduced and the PVC residue amount is decreased; The gun on-and-off points of rear quarter are cancelled and two adjacent seams are combined to one big seam. The result indicates that the solutions above remove the PVC residue on rear quarter and avoid the PVC interference to assembly installation surface.

Based on the existing wet spray booth scrubber system in the domestic automotive manufacturing industry, this study analyzes the wet eliminator to dry carton system proposal, modifies the exit structure and develops the targeted solutions according to different building height,spray booth width, layout and surroundings. At the same time, simulation software is used to simulate and optimize the field flow, in order to shorten modification cycle, reduce the investment cost and optimize the equipment.

This study first compared the material properties and costs to determine the use of 45% by mass glass fiber (GF) reinforced nylon (PA). Based on the envelope, electrical performance, and insulation requirements given by the battery system,the structural design scheme of the integrated insulation structure battery housing has been determined. CAE analysis was conducted on this housing with integrated insulation structure. Equal proportion samples of the composite housing were manufactured using LFT-D technology and the insulation structure was integrated. Corresponding CFD analysis and insulation performance testing were carried out; Simulation analysis and sample testing have proven that the mechanical and insulation properties of this housing meet the design specifications, and compared to aluminum alloy housing, the housing also has the advantages of lightweight and low cost.