As a core load-bearing component of the vehicle, the lightweight and reliability design of the air suspension integrated axle housing is crucial for improving overall vehicle performance. Addressing the limitations of traditional design methods in adapting to complex dynamic loads, this paper proposes a topology optimization method based on dynamic load spectra and the SIMP (Solid Isotropic Material with Penalization) method for non-uniform material distribution. A multi-condition topology optimization strategy applicable to diverse engineering scenarios is established. During the optimization process, the material density is adjusted iteratively based on analytical results to progressively refine the structure, ultimately achieving the optimal material distribution for the integrated axle housing. The study demonstrates that this method significantly reduces the axle housing mass by 90 kg while meeting strength and fatigue life requirements, providing an effective solution for lightweight design of air suspension integrated axle housings.

To achieve accurate prediction of aluminum alloy formability limits, a material hardening model based on the interpolation method of measured stress-strain data was proposed. The theoretical formability limit predictions of measured data, the power exponential, and cubic polynomial hardening models were systematically studied using the M-K theory. Uniaxial tensile tests were conducted to obtain stress-strain data of 6016 aluminum alloy, based on which different material hardening models were constructed. Detailed calculation procedures for limit strains under various models were presented, and forming limit diagrams (FLDs) were plotted. Finally, experimental results of aluminum alloy sheet formability limits were obtained through punch bulging tests and optical non-contact measurement techniques. The results indicate that the material hardening model based on the interpolation method of measured data demonstrates superior prediction accuracy, showing perfect agreement with experimental results. In contrast, commonly used power law and cubic polynomial curve-fitting hardening models tend to overestimate formability limits, particularly under negative strain path conditions. Material hardening models significantly influence the prediction of forming limits for 6016 aluminum alloy sheets, with prediction accuracy positively correlated with the goodness-of-fit of the hardening model fitting curves.

To facilitate the green transformation of the automotive industry, this study investigates the application of Biomass-modified Polypropylene (Bio-PP) in automotive interior and exterior components. It analyzes the processing techniques and material properties of PP modified with biomass fillers such as straw and coconut shell fibers. The results indicate that Bio-PP components offer advantages in lightweight design and reduced carbon emissions while meeting performance requirements. Despite challenges such as balancing cost and performance, Bio-PP holds promise as a key sustainable material for automotive applications.

In this paper, a systematic study of niobium-vanadium composite microalloyed aluminum-silicon coated hot-forming steel 34MnB5NbV is carried out by various material mechanical property tests and microstructure characterization methods, such as room temperature tensile test, three-point bending test, scanning electron microscope, and transmission electron microscope. The results show that after quenching, the yield strength of the material is 1 365 MPa, the tensile strength is 2 056 MPa, the elongation is 4.9%, and the bending angle is 58.7°. After bake hardening process, the yield strength of the material is increased by 127 MPa, the tensile strength is decreased by 144 MPa, the elongation is increased by 0.5%, and the bending angle is increased by 6.1°. After niobium-vanadium composite microalloyed 34MnB5NbV steel hot forming, the precipitation phase is (Nb, V) C composite precipitated phase, which has better fine grain strengthening and precipitation strengthening effect to improve the strength and toughness of the hot forming steel, so that the comprehensive mechanical properties achieve better. Moreover, in order to fully evaluate the bending toughness of the material, the three-point bending test is carried out on the door anti-collision beam part made by 34MnB5NbV steel. The maximum bending force and bending energy of the part showed significant improvements compared to those of the 1 500 MPa part, indicating good bending toughness and meeting the application requirements.

To investigate the influence of an ultraviolet (UV) coating on the bonding performance between the polypropylene housing and the polycarbonate lens of automotive lamps, this study prepares standard shear specimens with and without a sprayed UV coating. Two mainstream adhesive types in the lamp industry including a room-temperature curing sealant (cold adhesive) and a hot-melt adhesive (hot adhesive), which are evaluated by systematically assessing their shear strength after exposure to six harsh environmental conditions. The results show that the shear strengths of both the cold and hot adhesives under all environmental conditions significantly exceed the design requirement, indicating that the presence of a UV coating doesn't negatively affect the bonding performance of either adhesive type.

To study the application performance of galvanized hot-formed steel, the usage performance of pure zinc-coated hot-formed steel is analyzed from aspects such as welding, bonding, coating, and hot stamping. Some of the usage performances are compared and analyzed with those of aluminum-silicon-coated hot-formed steel. The results show that the galvanized hot-formed steel has excellent spot welding, bonding and painting performance, which is comparable to that of the Al-Si coated hot-formed steel. Among them, the electrophoretic corrosion resistance of the pure zinc coating is significantly better than that of the Al-Si coating, which can better improve the anti-corrosion performance of the vehicle body. The hot stamping performance of the galvanized hot-formed steel is good, and no cracking occurs after forming, and the depth of the micro-cracks under the coating is less than 10 μm. Under the existing working conditions, the galvanized hot-formed steel can obtain good stamping, bonding, welding and painting performance.

As the automotive industry accelerates its transformation toward intelligence, digitalization, and flexibility, logistics simulation technology centered on Plant Simulation has gradually become a core tool for factory material flow design and production capacity optimization. Taking the welding workshop of a specific vehicle model as an example, this paper systematically analyzes the principles, business processes, project prerequisites, and model construction of logistics simulation technology. It focuses on discussing simulation optimization scenarios such as full-line output simulation, single-factor multi-level experiments, and multi-factor cross-validation. Additionally, it comprehensively introduces 2 forward-looking trends in logistics simulation technology: sequential production for cost reduction and efficiency improvement, and real-time linkage between digital twins and Internet of Things (IoT) data.

In order to improve the performance, life and reduce the cost of Proton Exchange Membrane Fuel Cell (PEMFC), the key materials and technological progress of Membrane Electrode Assembly (MEA) are reviewed. Results show that the catalyst layer reaction efficiency and mass transfer capacity can be improved effectively by using mesoporous carbon support, high activity low platinum catalyst, high oxygen permeability ionomer and optimized three-phase interface structure; the development of thin and high temperature Proton Exchange Membrane (PEM) can reduce ohmic loss and broaden the operating temperature window; the thin and integrated Gas Diffusion Layer (GDL) is designed to enhance the reaction gas transport and water management. While these material technologies show promise in advancing fuel cells toward low-platinum, high-performance, and long-life, they still face problems such as low durability, high cost, and lack of large-scale production. Future research should focus on material innovation, structural optimization, and process breakthroughs to accelerate the commercialization of fuel cells.

As a core component of high-temperature proton exchange membrane fuel cells, membrane materials determine the commercial viability of hydrogen energy in the commercial vehicle sector, particularly in terms of their high-temperature stability, adaptability under dynamic operating conditions, and cost. Therefore, this paper reviews the technological evolution of high-temperature proton exchange membranes from laboratory research to automotive engineering applications. The performance characteristics and degradation mechanisms of perfluorinated composite membranes, phosphoric acid-doped polybenzimidazole membranes, and novel composite membranes under typical commercial vehicle operating conditions are analyzed. The compatibility bottlenecks between membrane materials and fuel cell systems are examined, along with optimization pathways for better integration. Solutions are proposed from three dimensions: material structural design, preparation process innovation, and system integration synergy. Future development directions, such as digital monitoring and green low-carbon manufacturing, are also discussed.

Traditional CAE modeling of door structures typically employs uniform wall thickness properties, failing to account for thickness variations after sheet metal forming. Therefore, it is of practical significance to develop a structural CAE model that incorporates the non-uniform wall thickness resulting from the forming process of door inner and outer panels. This paper investigates a method for constructing a structural CAE model of aluminum alloy door panels with non-uniform thickness based on forming analysis. In this model, the wall thickness properties of the inner and outer panels are assigned the non-uniform thickness values obtained from formability CAE analysis. A comparative analysis is conducted between the calculated stiffness and experimental stiffness of the aluminum alloy door panels using both uniform and non-uniform wall thickness CAE models. The results show that, compared to the uniform thickness CAE model, the structural CAE model based on forming-induced non-uniform thickness significantly improves the accuracy of door stiffness predictions. Specifically, the accuracy of torsional stiffness calculations at the upper corner point increases by 10.6%, at the lower corner point by 6.3%, at the outer waistline by 5.2%, at the inner waistline by 5.5%, at the upper mounting point of the window regulator by 7.7%, and at the lower mounting point of the window regulator by 7.5%.