1. Overview: 2. Background: Automotive headlamps are crucial for nighttime safety and vehicle aesthetics. Historically, halogen and xenon bulbs were prevalent, but halogen bulbs are inefficient, generating significant heat, while xenon bulbs have slower ignition times. High-Power Light Emitting Diodes (HPLEDs) offer higher efficiency and longer lifespans, but their compact size leads to high junction
1. Overview: 2. Research Background: The increasing need to reduce CO2 and SO2 emissions due to climate change necessitates improvements in electric vehicle efficiency. While Brushless Direct Current (BLDC) motors are widely used in EVs due to their high power density, efficiency, and reliability, their operational lifespan is limited by high internal heat generation and
1. Overview: 2. Research Background: This research investigates the impact of rapid injection speed on the quality of magnesium alloy vacuum die castings using AZ91D magnesium alloy. Magnesium alloys are widely used in aerospace, 3C industries, and more due to their high specific strength, stiffness, impact resistance, electromagnetic shielding, thermal conductivity, and recyclability. Existing vacuum
1. Overview: 2. Research Background: High-performance conductors are essential for economically and environmentally sustainable electricity transfer in modern infrastructure, manufacturing, and transportation, including electric vehicles. While copper has been the traditional conductor of choice, aluminum offers significant advantages in terms of cost and weight reduction for electricity transmission and distribution. Over 14% of global aluminum
1. Overview: 2. Research Background: Automotive headlamps are crucial for driver visibility, and LED lamps are gaining popularity due to their energy efficiency and long lifespan. However, the high heat generation of LED lamps can reduce their lifespan and efficiency. Existing water-cooled cooling plates and heat pipes offer superior cooling performance but are limited by
1. Overview: 2. Background: High-brightness white light-emitting diodes (LEDs) are very promising in many new illumination applications. LED light sources offer advantages such as long lifespan, fast response speed, environmental friendliness (mercury-free), and a color temperature (5500K-6000K) closer to natural light than xenon sources (4000K). The increasing use of LEDs in automotive lighting (interior lights,
1. Overview: 2. Research Background: Induction Motor (IM) drives are a crucial technology in modern industry, powering various applications including material handling, food and beverage processing, and electric transportation systems like EVs and e-trucks. Recently, there’s a growing focus on high-efficiency IM drive systems to reduce energy and fuel consumption, aligning with global sustainability initiatives.
1. Overview: 2. Research Background: The research addresses the growing global energy demand, projected to increase by 33% by 2050 [1]. A significant portion of energy is wasted as low-grade waste heat in industries like manufacturing and power generation [2, 4]. Conventional waste heat recovery (WHR) methods using heat exchangers often face challenges such as
1. Overview: 2. Background: Heating, ventilation, air-conditioning, and refrigeration (HVAC&R) systems consume a significant portion of residential and commercial building energy. Reducing refrigerant charge to mitigate greenhouse gas emissions is a crucial objective. Traditional heat exchangers (HXs) using round tubes and fins have limitations in performance improvement and require further miniaturization to meet reduced refrigerant
1. Overview: 2. Research Background: The demand for heat sinks across various industries (e-mobility, telecommunications, electronics, etc.) is significantly increasing, along with stricter performance requirements. A primary requirement for heat sinks is high thermal conductivity. Pure aluminum exhibits excellent thermal conductivity (247 W/mK), but it’s challenging to cast and possesses low strength. Typical die-casting alloys
![Figure 5 Aluminum wiring in automotive vehicles: a time line of application of aluminum in automotive wiring, reproduced from [53]; b high-strength aluminum alloy wire installed in the engine harness, reproduced from [57]; c die-cast aluminum coil for motor winding with seven turns and a conductor height of approx. 1.5 mm along with d coil arrangement, reproduced from [264]; e hairpin motor using aluminum V-cat windings, reproduced from [59]; f insulated and bare AA1350 aluminum of 7 AWG square tested for hairpin winding of electric motors and copper wire for comparison along with stress vs strain elongation curves, reproduced from [11].](https://castman.co.kr/wp-content/uploads/Figure-5-Aluminum-wiring-in-automotive-vehicles-570x342.webp)
![Figure 1. Fin designs on heat sinks: left with all parallel fins, right with angled fins increasing turbulence in the air (cooling medium) and increasing air exchange between the fins to maximize cooling [2].](https://castman.co.kr/wp-content/uploads/image-114-570x287.webp)