Characterization
Phase 1
Design and Fabrication
Phase 2
Background/Inspiration
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Design Requirements
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Characterization
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Interpretations
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Screening
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Materials/Treatments
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Force Diagrams
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Final Testing
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Background/Inspiration
Analyzing potential weight savings for our Baja SAE vehicle, we determined the upper control arm was likely too bulky for its observed loadcase.
Design Requirements
We then dissected the component and determined all relevant load cases to inform potential design decisions. Forces, fatigues, corrosion resistances, etc.
Characterization
We prepared samples for metallography, then took images under the SEM and OM. Determining the previous microstructure would help us identify material and any previous treatments.
Interpretations
The hypoeutectoid structure and Cr/Mo presence indicated air-cooled 4130 welds. From this, we identified weaknesses in stress concentrations and hardness nonuniformities, supported by prepared mechancial samples.
Screening
Brainstorming materials, we screened potential candidates via Ashby plots, then created a Figure-of-Merit equation to rank potential options.
Materials/Treatments
In accordance with literature on aluminium alloys, we designed a solution treatment and aging steps to achieve a T6 temper, preparing naturally aged and freshly-quenched control samples in parallel for mechanical comparison. This was paired with appropriate microstructural analysis.
Force Diagrams
Receiving the design, we performed FEA, and also first-principles frame analysis that gave us a general withstandable force based on observed material strength.
Final Testing
Ultimately, we testing our component on the vehicle and determined usability, diagnosing and performing RCA on any mechanical failures.