Failure Analysis and Material Optimization of Automotive Drive Shaft: A Review

Automotive drive shafts transmit torque from the engine to the wheels and are critical to vehicle performance. This paper reviews failure mechanisms and material optimization techniques for drive shafts. Conventional steel shafts, although strong, increase vehicle weight and are prone to fatigue failure under cyclic loading, typically initiating at stress concentration regions. Recent studies focus on composite materials such as carbon fiber reinforced polymer (CFRP) and glass fiber reinforced polymer (GFRP) due to their high strength-to-weight ratio and improved dynamic performance. Finite Element Analysis (FEA) is widely used to evaluate stress, deformation, and vibration behavior. Literature shows that composite shafts offer reduced weight, higher natural frequencies, improved fatigue resistance, and better vibration damping compared to steel shafts. This review highlights key research findings and identifies challenges in experimental validation and manufacturing for future development.