To explore the application of micro foaming blow molding technology in automotive air ducts,this paper adjusts the blowing presstre and temperature in the production process to obtain qualified samples and rerifies their material properities and product performance. The results show that, compared with the unfoamed air duct, air duct parts with foaming ratio of 10% experience significant degrease of tensile and bending performance, with performance degradation up to 40%. In the foaming ratio range between 10% to 30%, with the increase of foaming ratio, the tensile and bending performance of the air duct material gradually decrease, but compared with tensile strength, the bending strength decreases more slowly. The air duct with foaming ratio of 30% not only meets the appearance requirements, but also meets the product performance requirements for automotive products. At the same time, by trial production of air ducts with different structures, the design points of microfoaming air duct are summarized.

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.

In this study, taking the sealing structure of oil pump flanges as the research object, a rough peak contact model and a parallel flat plate leakage model are further established to calculate the leakage rate of the sealing surface based on the contact pressure distribution on the sealing surface obbtained by finite element mechanical analysis. At the same time, the time-temperature equivalent model of rubber performance is established by rubber accelerated aging test so as to predict rubber sealing life. Finally, the rubber sealing life is verified by seal leakage rate bench test, proving that the test result is basically consistent with the prediction result.

For the instrument panel beams made mainly of steel, aluminum-magnesium alloy, and composite material, this paper compares the instrument board beams of different processes in terms of lightweight, accuracy, and cost, studies and analyzes the use scenarios and application trends of instrument panel board, and compares the technical defects and process restrictions of different types of instrument panel beams. The study believes that with the general use of composite material beams, the cost advantage of steel beams and the lightweight advantages of aluminum-magnesium alloy beams will no longer be significant, while composite material beams will become the mainstream trend of process manufacturing.

To obtain high-performance heat-treated free aluminum alloys, 3 kinds of Al-Si based heat-treated free aluminum alloys with different composition ratios are designed by adjusting the mass fractions of each element in the alloy. The melting temperature range, structure phase composition, fracture morphology, tensile and fatigue performance of 3 kind of alloys are analyzed by using Differential Scanning Calorimeter (DSC), metallographic microscope, scanning electron microscope, tensile testing machine and electromagnetic resonance fatigue testing machine. The results show that 2# alloy has good casting fluidity, metallographic structure, comprehensive strength and toughness properties and casting manufacturability, with a melting temperature range of 55 ℃, the tensile strength, yield strength and elongation rate at break are 303 MPa, 153 MPa and 11.3%, respectively. The average axial tensile compressive fatigue strength at 1×10⁷ cycles is 125 MPa, which is superior to the fatigue performance of AlSi9Cu3 (Fe) die-casting alloy commonly applied in the automotive industry.

To address the issue of low efficiency and great subjective influence while the laborer using the oilstone to polish the surface defects of Body-In-White（BIW） parts, this paper proposes a virtual oilstone detection method, and elaborates a data 3D system based on a high-precision 3D scanner data acquisition and automatically analyzes the algorithm and steps of surface defects on automotive panels and BIW. Simulation experiments and online detection experiments of virtual production lines are used to verify the method. The results show that this method can detect BIW surface defects stably and improve the efficiency and accuracy of surface quality detection on the automotive production line.

In order to maximize the efficiency of gear oil and improve the transportation efficiency and economic benefits of users, an on-line monitoring technology of commercial vehicle transmission and drive train oils is developed to monitor the status parameters of gear oil in real time to change oil according to its quality. The test results show that there is a strong linear relationship between dynamic viscosity and kinematic viscosity of gear oil at different temperatures, and dynamic viscosity can replace kinematic viscosity during viscosity calculation. The variation of dielectric constant with temperature, water content, Fe content and acid value content is obvious, which verifies the feasibility of using dielectric constant as a comprehensive evaluation index of gear oil quality, and provides the experimental research basis for multi-parameter online monitoring of gear oil.

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 order to improve exterior color quality control and management effect, the management methods of quality control for vehicle exterior color before and after mass production are summarized. Based on the practices, the method combined with color characteristics analysis is proposed. The key characteristic data are analyzed and control standards are established, which aims to improve the recognition efficiency of new vehicle exterior color quality and prevent the occurrence of batch color difference accident.