Bimetallic Strip-Based Radiator Cap Safety Mechanism: Design, Implementation, and Analysis

Author(s)	Mr. Sivaa Maaran Vijayakumar, Ms. Yogalakshmi Kumaravelan
Country	India
Abstract	This paper presents a novel safety mechanism for radiator caps that prevents accidental opening when coolant temperatures reach elevated levels. The design utilizes bimetallic strips composed of steel and brass to create a temperature-responsive locking mechanism. When exposed to excessive heat, the differential thermal expansion between the metals causes the strip to deflect and engage with grooves on the radiator neck, preventing the cap's removal until safe temperatures are restored. This passive safety system requires no electronics, reducing complexity while enhancing reliability. Comprehensive testing demonstrates the mechanism's effectiveness across a range of operating conditions, with consistent engagement at 90°C and disengagement at 75°C. The design can be retrofitted to existing vehicles or integrated into new models with minimal modification to current radiator systems
Keywords	Safety mechanism, Radiator cap, Bimetallic strips, Temperature-responsive locking, Thermal expansion, Passive safety system, Reliability
Field	Engineering
Published In	Volume 8, Issue 2, March-April 2026
Published On	2026-03-03

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