Nowadays the automotive industry is mainly focused on competition, and this fact forces vehicle producers to constantly look for improvements in the areas of quality and reliability. Life-span, flawless operation, and safety are directly interconnected. Therefore, much attention and resources are spent on research factors that affect the stated properties. Significant capital is invested in the optimization of the constructional solutions and innovative material applications related to the safety and durability of the constructions. This paper presents the results obtained while developing a new ecological three-wheeled vehicle. The main research areas were focused on replacing the original material with a light aluminum alloy, while achieving a substantial improvement in drivability for the three-wheeled vehicle by implementing a modified front wheel steering system. The submitted research achieved a weight reduction of the frame by 40 kg by applying light material substitution (EN AW 6063.T66), which will naturally have a positive impact on the range of the designed electric vehicle; furthermore, we implemented an innovative steering mechanism optimized during the experimental operations.

The softening effect, which occurs as an undesirable consequence of microstructural changes in the heat-affected zone as a result of the welding process, is an inherent aspect of welding high-strength low-alloyed steels. One of the recommended ways to minimize these changes is the application of laser beam welding as a lower heat input technology. Hence, this work compares and investigates the effects of laser beam welding on the weld joint properties of S690QL, S960QL, S1100QL, S700MC, S960MC, and S1100MC steels. This research operates on the assumption that the mechanical properties of the zones surrounding the soft zone—base metal and weld metal—affect the mechanical properties of weld joints as well. The work shows that the total value of yield strength, tensile strength, and elongation of welded joints increases when the value of the strength of the weld metal and the soft zone increases and when the width of the soft zone narrows, and vice versa. Furthermore, the study demonstrates that the amount of C, Cr, Mn, Mo, Cu, and Ni in steel as well as the thermal cycle is directly associated to strength in these zones. The findings indicate that although the welded joints’ yield strength and tensile strength values remained over 96% of the base metal’s value, in certain cases the elongation values decreased to a mere 21% of the base metal’s value.

In this paper, a naturally pressurized gating system has been designed to reduce the turbulence of the melt during casting. The influence of gate dimensions, foam filters, a trident gate and a vortex element were evaluated. Their effect on melt velocity, flow characteristics, number of oxides, casting properties and mechanical properties were observed. ProCAST Simulation software v.2023 and a water flow test were also evaluated to assist in the experimental evaluation of the castings. Melts showed a relationship between melt velocity and porosity of castings. Quantitative evaluation of the surface porosity showed a trend of decreasing porosity with decreasing melt velocity. The greatest reduction in the melt velocity was achieved by a M4 design, which was associated with the highest reduction in the oxides. The pores analyzed proved the presence of oxide layers on their inner surface and a possible theory of pore formation when the initiator of porosity is entrained double oxide layers. The best metal yield was achieved with M1, but the difference between M2 and M4 was negligible (2–5% yield difference), so it can be stated that the beneficial effect of the M4 design in providing the best quality castings is not negated by the increase in metal yield.

The hypoeutectic aluminum alloy AlSi5Cu2Mg is used for the production of high-strength cylinder head castings. The alloy is unique for its specific low permitted Ti content (0.03 wt% max), which makes it impossible to refine the grain structure of this alloy using standard Al–Ti–B grain refiners. The specific chemical composition is specified by the supplier company. The aim of this paper is to find a suitable alloying element that would improve the selected properties (e.g., mechanical, and physical properties) that are crucial for cylinder head castings. The research focuses on the investigation of the effect of different Zr addition (0.05; 0.10; 0.15 and 0.20 wt% Zr in the form of AlZr20 master alloy) on the properties of AlSi5Cu2Mg in the as-cast state and after heat treatment T7. The obtained results showed that ultimate tensile strength, yield strength, hardness, and physical properties of as-cast samples do not change significantly with increasing Zr content. The experimental alloys showed a more significant increase in ultimate tensile strength, yield strength, hardness, and thermal conductivity after heat treatment T7. Zirconium-rich intermetallic phases were observed in the shape of separate thick needles or as a cluster of two crossed thinner needles.

The presented article includes a summary of the experimental works regarding the possibility of using and replacing more expensive primary alloys with secondary alloys. Although the use of secondary alloys is relatively widespread today, they ...