This article focuses on the fatigue performance of thin aluminum plate SPR riveted joint. Through a series of physical tests on the fatigue performance of thin aluminum plate SPR joint, the fatigue life relationship under tensile and shear loads are obtained. Based on the Rupp theory and combined with simulation method, the stress range and fatigue life relationship under tension and shear loads are obtained. Nine parameters of Rupp constitutive model are optimized using Excel & Hyperstudy, and a normalized S-N curve for the fatigue life of thin aluminum plate SPR joint is constructed. The fatigue life prediction method for thin aluminum plate SPR joint is established, supporting the forward design of thin aluminum plate SPR joint structure.

In the automotive painting pretreatment process, one-step phosphating method is suitable for bodies with an aluminum content of ≤40%, while two-step phosphating (phosphating + passivation) can handle high-aluminum or all-aluminum bodies. This paper compares their process characteristics, consumable consumption, and body appearance quality. Case analysis reveals that when the aluminum content is low (below 30% in this case), the two-step method consumes approximately 20% more materials per vehicle than the one-step method. Furthermore, the two-step process is prone to causing streaks and pit defects on the surface of aluminum outer panels after electrophoretic painting. These streak defects can be mitigated by optimizing phosphating parameters and spray processes, while pitting defects can be reduced by adjusting the aluminum sheet's Electro Discharge Texture(EDT) process. The research demonstrates that for production lines with low aluminum content, the one-step phosphating method holds significant advantages in both economy and final quality.

To investigate the film-forming performance of nickel-free phosphating on various substrates and its compatibility with coatings, this paper examines the characteristics of nickel-free phosphating films on cold-rolled steel sheets, hot-rolled steel sheets, and aluminum alloys, and evaluates their compatibility with electrophoretic paint and powder coatings. The results show that the performance of the nickel-free phosphating film on the tested substrates is comparable to that of ternary phosphating films, and it demonstrates good compatibility with both electrophoretic paint and powder coatings. Therefore, it can be applied to the pre-paint phosphating treatment of automotive components such as vehicle bodies and powder-coated frames.

To address the issue of large fluctuations in subjective odor evaluation within vehicles and the high difficulty in tracing the source and making rectifications, research on the objective evaluation of vehicle cabin odors is conducted. Gas Chromatography-Mass Spectrometry (GC-MS), high-performance liquid chromatography, and Gas Chromatography-Ion Mobility Spectrometry (GC-IMS) are employed to test the entire vehicle and its interior components such as seats, door panels, and instrument panels. Key odor-contributing substances are screened out through odor activity values. The results indicate that aldehydes, ketones, and acid esters are the core odor-contributing components, and the door panels have the highest odor similarity to the entire vehicle. A corresponding relationship between subjective odor perception and objective substance content is established. GC-MS and GC-IMS are able to achieve precise odor source tracing and verification of rectification effects, providing technical support for the control of in-vehicle air quality.

Currently, internal components of automotive lamps are primarily secured by methods such as snap-fit or mechanical fastening. However, snap-fit assemblies carry risks of material embrittlement and fracture, while mechanical fastening structures require reserved space for screw holes, leading to inefficient space utilization. These issues constrain the improvement of weight reduction and reliability in automotive lamps. To address these challenges, this paper proposes an adhesive bonding solution for lamp components based on ultraviolet (UV) -curable adhesive. Tests were conducted on the tensile strength, moisture resistance, high-temperature resistance, and thermal cycling performance of different adhesive materials, as well as the reinforcing effect of plasma treatment on the bonding interface. The test results indicate that UV adhesive can achieve a bonding strength of approximately 10 MPa when bonding plastic parts, demonstrating certain engineering feasibility. This provides a new technical pathway for upgrading automotive lamp manufacturing processes.

This paper addresses the issues of low offline program availability, long commissioning periods, and frequent equipment collisions in the commissioning phase of body integration projects. It proposes a systematic digital solution that integrates 3D large-space laser scanning, Delmia-based robot simulation, and EKS virtual commissioning with Scout verification. It achieved over 50% first-time utilization of robot offline programs and raised commissioning efficiency by approximately 30%. Statistical analysis further predicted the consistency between simulation model and actual conditions across the entire workshop and identified the influence of equipment type on deviations. The research provides an effective methodological reference for equipment installation and commissioning period reduction in body integration projects.

During the debugging of the trihedral turntable flexible switching system for BIW assembly, issues such as Z-axis clamping cylinder jamming, trolley position loss, and body dimensional deviation were identified. This paper proposes a systematic optimization approach. By introducing a Y-axis pre-positioning station and reducing motor torque, internal stresses within the frame are eliminated, thereby resolving cylinder jamming. The adoption of dynamic tolerance concepts and differential servo motor parameter settings for different vehicle models effectively prevents position loss. Additionally, optimizing the different vehicle sequencing strategy by implementing small-batch continuous production of identical models significantly reduces the switching frequency of the assembly system. Following implementation, the average daily downtime decreased from 36.7 min to 1.6 min. The research demonstrates that a combined approach of mechanical optimization and production sequence adjustment is an effective solution for mitigating downtime in complex flexible assembly systems.

The transmission is one of the core components of the automotive powertrain system, and the housing serves as a critical structural element. Its performance directly impacts power transmission efficiency, reliability, and driving comfort. This paper reviews research advancements in lightweight design, reliability analysis, casting processes, and vibration-noise control of transmission housings. The optimization of transmission housing structure can reduce weight and enhance durability, while increasing stiffness effectively suppresses radiation noise. Optimizing the stiffener, changing the cross-section design and changing the shell thickness with the help of simulation technology can greatly reduce the design difficulty, and the exploration of new materials will also become a research hotspot. Additionally, optimizing casting process parameters can shorten production cycle and improve casting quality. However, the best process parameters need to be further explored, and the combination of casting process and intelligent manufacturing technology in the future is worthy of in-depth study, which provides reference for improving the comprehensive performance of transmission housing.

The Microstructure, friction and wear reduction and noise performance of FAS3420 steel samples with different surface treatments are investigated using XRD, EDS, SEM, friction and wear testing, fatigue testing, and NVH measurements. The results indicate that after low-temperature ion sulfurization and magnetron sputtering treatment, a sulfurizing layer primarily composed of FeS formed on the surface of the carburized and quenched steel. Supported by a high-hardness fine-needle martensite structure, the friction coefficient and volumetric wear rate are significantly reduced, demonstrating improved friction reduction, wear resistance, and anti-seizure capabilities, which can effectively extend the fatigue life of shaft and gear components. Through the surface protection and repair effects of sulfide solid lubricating films, direct metal contact and collisions, impacts, vibrations, and other noises caused by gear wear and deformation are reduced, thereby achieving friction reduction and noise suppression.

As a critical functional component of the vehicle body, the automobile engine hood's point cloud registration accuracy directly impacts the assembly gap, sealing performance, and collision safety. To address the limitations of traditional registration methods in handling engine hood point clouds—such as large surface registration errors, low precision, and poor efficiency—this paper employs an improved voxel filtering approach for preprocessing and proposes a hybrid registration method based on feature fusion and GICP. The method first performs coarse registration through curvature feature extraction and FPFH descriptors, followed by fine registration using the GICP algorithm. Experimental results demonstrate that our approach achieves an average registration error of 15.11 mm with an average processing time of 9.3 s on a dataset containing 30 engine hood point clouds, showing higher registration accuracy and better computational performance compared to baseline algorithms. This study provides a novel approach for high-precision registration of complex curved surfaces in automotive panels.