Abstract: The instant disclosure relates to ductile iron alloy compositions and articles that can maintain desired microstructural and mechanical properties even when cast to make thin-wall samples. Particularly, the compositions herein may maintain hardness and ductility and minimize carbide formation even when cast in samples as thin as about 1 mm to about 6 mm. In particular, the instant disclosure relates to a cast iron alloy composition including nodular or spheroidal graphite domains comprising an iron content of at least about 90% by weight, a remaining alloy content of less than about 10% by weight, about 0.65% to about 0.85% by weight copper, about 3.6% to about 4.2% by weight silicon, and about 3.4% to about 3.8% by weight carbon.

Abstract: An alloy composite material comprising an aluminum alloy layer and a thermal spray alloy layer of 20 to 40% Mn and 47 to 76% Fe by weight in overlaying contact with the aluminum alloy layer. An alloy composite material comprising an aluminum alloy layer or base layer and a thermal spray alloy layer of 20 to 40% Mn and 47 to 76% Fe by weight in overlaying contact with the aluminum alloy layer or base layer. The aluminum alloy layer or base layer and the thermal spray alloy layer have a mechanical compatibility to each other of 20-60 MPa as determined using tests specified by ASTM-C633 test. A process of thermal spraying comprising providing a base layer and a feed stock alloy of 20 to 40% Mn and 47 to 76% Fe and thermally spraying the feed stock alloy onto the base layer to form an alloy composite material.

Abstract: An alloy composite material comprising an aluminum alloy layer and a thermal spray alloy layer of 20 to 40% Mn and 47 to 76% Fe by weight in overlaying contact with the aluminum alloy layer. An alloy composite material comprising an aluminum alloy layer or base layer and a thermal spray alloy layer of 20 to 40% Mn and 47 to 76% Fe by weight in overlaying contact with the aluminum alloy layer or base layer. The aluminum alloy layer or base layer and the thermal spray alloy layer have a mechanical compatibility to each other of 20-60 MPa as determined using tests specified by ASTM-C633 test. A process of thermal spraying comprising providing a base layer and a feed stock alloy of 20 to 40% Mn and 47 to 76% Fe and thermally spraying the feed stock alloy onto the base layer to form an alloy composite material.

Abstract: A method for steering pull compensation to maintain a steering load below a predetermined threshold value. A straight line driving condition is verified through vehicle sensors and/or GPS, drive torque control is performed such that the steering load is kept below the predetermined threshold value. The steering pull compensation method may be disabled by a vehicle operator and is disabled in the absence of a verified straight line driving condition.

Abstract: A system for decoupling steering rack force disturbances in electric steering may comprise a steering wheel angle sensor, a yaw rate sensor, a lateral acceleration sensor, and a steering torque sensor. The system may also comprise a tire force generator configured to receive signals from the steering wheel angle sensor, the yaw rate sensor, and the lateral acceleration sensor and send a reference rack force to a controller. The system may further comprise a rack force observer configured to receive signals from the steering torque sensor and send an estimated rack force to the controller, wherein the controller is configured to receive signals from the tire force generator and the rack force observer, compare the estimated rack force with the reference rack force to determine a rack force disturbance, and adjust an auxiliary torque based on the rack force disturbance.

Abstract: A system for decoupling steering rack force disturbances in electric steering may comprise a steering wheel angle sensor, a yaw rate sensor, a lateral acceleration sensor, and a steering torque sensor. The system may also comprise a tire force generator configured to receive signals from the steering wheel angle sensor, the yaw rate sensor, and the lateral acceleration sensor and send a reference rack force to a controller. The system may further comprise a rack force observer configured to receive signals from the steering torque sensor and send an estimated rack force to the controller, wherein the controller is configured to receive signals from the tire force generator and the rack force observer, compare the estimated rack force with the reference rack force to determine a rack force disturbance, and adjust an auxiliary torque based on the rack force disturbance.

Abstract: A method for steering pull compensation to maintain a steering load below a predetermined threshold value. A straight line driving condition is verified through vehicle sensors and/or GPS, drive torque control is performed such that the steering load is kept below the predetermined threshold value. The steering pull compensation method may be disabled by a vehicle operator and is disabled in the absence of a verified straight line driving condition.

Abstract: A method of performing manufacturing operations on a workpiece made of a high strength alloy is disclosed in which a local area of a workpiece is heated to micro-structurally soften the local area. The local area of the workpiece becomes softened and more ductile. A manufacturing operation involving deformation of the heat softened area is performed with the metal in the heat softened region being more ductile and having less strength than the surrounding portions thereof. Manufacturing operations may include riveting, clinching, hydro-forming, and magnetic pulse joining.

Abstract: A crush rail or other structural member of a vehicle is provided with crush triggers. The crush triggers are formed by heating localized areas of the crush rail or other part and allowing them to cool slowly to provide increased ductility and reduced strength in a localized region. The crush rail is designed to collapse in a series of convolutions in a regular and repeated pattern. Crush triggers may be provided on body pillars, steering columns, drive shafts, engine support cradles, and other parts of a vehicle. A plurality of crush triggers may be provided on a single structural member depending upon impact absorption requirements.

Abstract: A crush rail or other structural member of a vehicle is provided with crush triggers. The crush triggers are formed by heating localized areas of the crush rail or other part and allowing them to cool slowly to provide increased ductility and reduced strength in a localized region. The crush rail is designed to collapse in a series of convolutions in a regular and repeated pattern. Crush triggers may be provided on body pillars, steering columns, drive shafts, engine support cradles, and other parts of a vehicle. A plurality of crush triggers may be provided on a single structural member depending upon impact absorption requirements.

Abstract: A method of performing manufacturing operations on a workpiece made of a high strength alloy is disclosed in which a local area of a workpiece is heated to microstructurally soften the local area. The local area of the workpiece becomes softened and more ductile. A manufacturing operation involving deformation of the heat softened area is performed with the metal in the heat softened region being more ductile and having less strength than the surrounding portions thereof. Manufacturing operations may include riveting, clinching, hydro-forming, and magnetic pulse joining.

Abstract: A vehicle brake assembly includes a brake rubbing interface operative to slow a vehicle when activated. The interface produces airborne brake dust particles when activated. A dust collector plate is positioned in close proximity to the brake rubbing interface to collect the brake dust. A charging circuit is operative to generate an electrostatic charge so that the brake dust is attracted to the charged collector plate.

Abstract: A vehicle brake assembly includes a brake rubbing interface operative to slow a vehicle when activated. The interface produces airborne brake dust particles when activated. A dust collector plate is positioned in close proximity to the brake rubbing interface to collect the brake dust. A charging circuit is operative to generate an electrostatic charge so that the brake dust is attracted to the charged collector plate.