Analysis of thermal shock on automotive component

The project is carried out in two phases: the first aims at reproducing the thermo-mechanical behavior of the component during a standard test for automotive thermal shock components in the range -40 ° C + 120 ° C; the second one aims to explain the formation of a crack in the resin covering the metal windings and to propose solutions to avoid this repeatable breakage.

After calculating the temperature distribution, the deformations and the stresses in all the components during repeated heating-cooling cycles, the critical areas within the epoxy resin responsible for the beginning of the cracking that is then propagated to the surface have been identified free assembly.

The resin yielding mechanism has been identified: due to the different coefficients of thermal expansion of the magnetic core, of the plastic housing and of the epoxy resin, tensile stresses are generated which are greater than the limit of the material during the heating phase.

By analyzing the behavior of different resins we have therefore identified a valid substitute that avoids the recurrence of the defect found.