The architectural evolution of the electric vehicle (EV) has transformed the battery pack case (BPC) from a simple storage vessel into a high-performance structural component that is fundamental to vehicle safety, range, and longevity. As the automotive industry shifts toward dedicated electric platforms, the battery enclosure has become the cornerstone of the vehicle’s underbody, bearing significant mechanical, thermal, and vibrational loads while simultaneously acting as a hermetic barrier for sensitive lithium-ion cells. Within this complex ecosystem, the humble fastener has transitioned from a standard "C-part" to a safety-critical engineering solution. [...]

Abstract The engineering imperative for lightweighting in the automotive and aerospace sectors has necessitated the extensive use of multi-material assemblies, frequently coupling aluminum and magnesium alloys with high-strength steel fasteners. However, the juxtaposition of these metals in the presence of an electrolyte initiates galvanic corrosion, a process characterized by accelerated anodic dissolution that can compromise structural integrity. Fasteners are uniquely susceptible to this phenomenon due to the unfavorable area ratio—the "small anode, large cathode" effect—which concentrates corrosion current on the fastener or its immediate interface. This paper provides a comprehensive [...]

The integrity of mechanical structures, from heavy industrial machinery to aerospace components, depends fundamentally on the reliability of bolted joints. The primary goal of any tightening process is to achieve a specific level of tension, or preload, in the bolt. This tension creates a clamping force that holds the components together, resisting external loads, vibration, and thermal expansion. However, in most industrial applications, tension is not measured directly; instead, torque is applied as a proxy. This transition from rotational force to linear tension is governed by a complex set of [...]