lightweight vehicle manufacturing: joining & forming focus 2015

Reducing The Cost Of Multi-Material Lightweight Joining & Forming: Created Specifically For The Manufacturing Job Functions

Demonstrating The Very Latest OEM Case Studies And Technical Advances Being Applied To

Reduce The Costs And Cycle Times Of Mixed Material Joining And Forming To Enable The Implementation Of Lightweight Materials In High Volume Vehicle Production

Designed Specifically For Joining, Forming & Manufacturing Engineering Professionals:

April 14-15 | Detroit | Michigan, USA

Mark Keller Manager of Truck Body Structures and Closures Department Ford

Over 20 OEM Led Case Studies Presented By the Leading Experts Based On The Most Advanced Manufacturing Practices

M Follow us @AutomotiveInnov

www.global-lightweight-vehicle-manufacturing.com

Register By FridayFebruary 27, 2015

SAVE $400

• JOINING ALUMINUM & ALUMINUM: Determining the most cost effective methods for joining aluminum to aluminum based on joint: strength and load carrying capability, fatigue strength, and crash resistance

• JOINING ALUMINUM to STEEL: Reviewing welding methods for joining aluminum with conventional and new grade steels to determine which technology is most effective - cost, corrosion risk and volume capability

• CORROSION PROTECTION & COATINGS: Understanding which corrosion mitigation processes are being used to maximize long-term performance of joints in lightweight vehicles

• MATERIAL CHARACTERIZATION: Evaluating properties of the new grades of UHSS, aluminum and composites to determine their influence on the selection of multi-material joining and forming technologies

• PROCESSING ADVANCED COMPOSITES: Understanding how costs and cycle times are being reduced to speed up composite forming to justify the business case for their use in mass produced vehicles

• AUTOMATION: Hearing how OEMs are automating typically manual processes to improve cycle times and reduce costs of lightweight vehicle production

• UPCOMING TECHNOLOGICAL ADVANCES AND THE NEXT STEPS IN LIGHTWEIGHTING: Examining the very latest joining and forming innovations that could revolutionize costs and discussing what needs done as an industry to reduce costs in the next 3 years

Robert Saje Design Engineer for Structures Cadillac

Fei Xiong Technology Director of Material Engineering R&D Centre Geely

Pete Edwards R&D Leader for Joining Honda Engineering North America, Inc.

Gregory E. Peterson Senior Technology Specialist Lotus Engineering

Michael Danyo Aluminum Technology Launch Supervisor Ford

Surender Maddela Senior Research & Development Engineer, Materials Engineering Nissan Motor Corporation

Organized By:

Mark Voss Engineering Group Manager Body Advanced Technical Works GM

EXCLUSIVE VEHICLE MANUFACTURER

RATES AVAILABLE


SAVE $400

Regardless of how different the vehicle design is, how advanced the manufacturing plant is and

how large the budget is, every large scale OEM in the US, Europe and Asia is working towards

every single one of these goals.

Every OEM is researching and testing and piloting to figure out three key things:

• Which joining and forming techniques deliver the highest performance at the lowest costs

on different advanced lightweight materials

• In which parts of the vehicle can these techniques be most cost effectively applied

• How can they be implemented quickly and cost effectively into the production line

Everyone has their own answers, but with technology and understanding advancing at break

neck speed each year, what was the best today is rarely the best tomorrow.

The US-Wide Weight Reduction Drive Advances At Pace

The U.S. Environmental Protection Agency (EPA) and the Department of Transportation’s

National Highway Traffic Safety Administration (NHTSA) are issuing final rules to extend the

National Program to further reduce greenhouse gas (GHG) emissions and improve fuel

economy for model years 2017 through 2025 light-duty vehicles. These are projected to

result in an average industry fleet wide level of 163 grams/mile of carbon dioxide (CO2) in model

year 2025 (equivalent to 54.5 mpg vs. 29 mpg in 2013). With these regulations in place, OEMs

are under increasing pressure to further explore all possible methods and strategies that will help

ensure these stringent standards are cost effectively met. OEMs have ranked “meeting of the

fuel efficiency and emission targets” as the top challenge that they presently face.

The Integral OEM-Led Joining And Forming Knowledge Exchange Returns To Detroit – 2nd Year Running

After resounding success in its launch year, Lightweight Vehicle Manufacturing: Joining &

Forming Focus 2015 is returning in its second year to equip joining, forming and manufacturing

engineering professionals with the very latest case-study based knowledge and shared

advanced practices. The carefully selected expert OEM speakers will critically inform delegates

about their expeiences in selecting the most suitable methods for joining and forming parts and

components made from mixed materials, and how to efficiently and cost-effectively introduce

them into the assembly lines.

Meet Decision Makers From:

• Local and International OEMs

• Tier 1 Suppliers

• Material Suppliers

With The Following Job Titles:

Technical Directors, General Managers, Department Managers, Senior Engineers, Senior Specialists, Technical Specialists, Senior Researchers from...

• Joining• Welding• Bonding• Adhesive• Stamping• Forming• Corrosion• Coatings• Simulation• Self Piercing Rivets• Assembly• Implementation• New Technologies• Fastening• Technical• Frame• Quality• Sheet Metal• Manufacturing Engineering• Project Engineering• Product Engineering• Lightweight Engineering• Operations/R&D Centers

Plus:• Welding Suppliers (Ultrasonic Welding,

Laser Welding)• Bonding Suppliers• Fastening Suppliers (SPRs)• Adhesive Suppliers ....• Forming Technology Suppliers• Coatings/ Corrosion Protection• Component Suppliers• Additive Manufacturing For Vehicle

Components/DMLS• Steel Suppliers• Aluminum Suppliers• Magnesium Suppliers• Advanced Composite Suppliers (i.e.

Carbon Fiber Composites)• Recycling/Scrap Metal

VENUE INFORMATIONThe Westin Southfield Detroit Hotel1500 Town Center

Southfield, MI 48075, USA

Tel: 1 248 827 4000

Web: www.westinsouthfielddetroit.com

www.global-lightweight-vehicle-manufacturing.com (1) 800 721 3915 [email protected]

Reducing costs. Reducing cycle time. Joining mixed materials in high volume. WHO SHOULD ATTEND

Tier1 partners must attend this event to understand what their customers are striving for as well as gain valuable network connections.

Technical Lead - Materials for Advanced Technology & Research (AT&R), Volvo Group Trucks Technology


SAVE $400

• “WHY” FOCUSED: All presentations are designed not only to explain which technology

choices have been made in lightweighting, but also, importantly, each presentation will come

with an explanation on why certain decisions have been made, to enable the transferability of

lessons

• “NEXT STEPS” FOCUSED: This conference isn’t a selection of presentations

demonstrating old case studies in lightweighting. It is focused on new, pioneering and

progressive case studies from those who are making the next big steps in lightweight vehicle

manufacturing

• MULTI-MATERIALS FOCUS: Presentations will focus on the most challenging aspect of

lightweighting: optimizing the combined application of steel, aluminum and composites to

enable design of the lowest weight body architecture

• DESIGNED FOR JOINING AND FORMING JOB FUNCTIONS: Due to popular

demand as a part of the GALM series, a very unique niche conference has been developed

to add value to the forming and joining professionals working on the manufacturing side of

the lightweight vehicles production. No similar conference will provide the same depth of

knowledge and level of details to aid the cost effective and process efficient adoption of new

technologies

• OEM LED: Based on the detailed consultation with OEMs, the agenda content is purely

industry driven with the program designed to uncover opportunities with optimizing the

manufacturing process of vehicles from mixed lightweight materials

• FOCUSES ON CASE STUDIES AND PROVEN METHODS: All participants will benefit

from evaluating the most advanced technologies used and assessing the effectiveness of

innovative methods adopted in the lightweight automotive production with a chance to apply

them in their daily operations to maximize output and efficiency

• COST REDUCTION FOCUSED: With the automotive focus on cost competitiveness being

ever more prominent, uncovering areas that could add substantial reductions in manufacturing

costs become an exceptionally appealing angle that will be thoroughly scrutinized during

Lightweight Vehicle Manufacturing: Joining & Forming Focus 2015


WHAT’S SPECIAL ABOUT LIGHTWEIGHT VEHICLE MANUFACTURING: JOINING & FORMING FOCUS 2015

I was attracted by increasing my knowledge of material choice as well as discussing in depth issues such as cost and recyclability. Good scope of presenters.

Engineer - Roof Systems, Bentley Motors

MULTI-MATERIAL LIGHTWEIGHT JOINING TECHNIQUES Day 1Tuesday April 14 , 2015

8.30 Chair’s Opening Remarks

KEYNOTE: ADVANCES IN MIXED MATERIAL JOINING

8.40 Showcasing The Cadillac Manufacturing Strategy That Enabled Blending of Wider Range Of Lightweight Materials In The CT6 Topping Car Structure: New Materials Joining Techniques Focus

•SharingCadillac’sadvancementoftheapproachtolightweightmaterialsintroductionintothecarbodyasthenextphaseofitsgrowingproductsubstance

•AssessingCadillac’smixedmaterialarchitecturestrategytofreeengineerstoselecttheoptimalmaterialforthespecificpurposeineachareaofthecar

•Introducingnewinnovativematerialjoiningtechniquestoenableblendingofmaterialusagebeyondthetraditionaladherencetoaprimarysteeloraluminumstructure

•ExploringCadillac’snewCT6range-toppingcar,thefirstmodeltoadoptthisnewdesignphilosophyandoutliningCadillac’svisionforthefutureofthisadvancedtechnologyuseanditsfurtherdevelopment

Robert Saje, Design Engineer for Structures, Cadillac

9.10 Question & Answer Session

JOINING METHODS: HIGH VOLUME ALUMINUM BIW PRODUTION

9.20 Evaluating, Which Joining Methods Were Proven Most Effective And Cost-Feasible In The Ford F150 Aluminum BIW: Case Study

•ReviewingtheprosandconsofthejoiningmethodsusedinthehighvolumealuminumFordF150BIW:

•Adhesivebonding•SelfPiercingRivet(SPR)•FlowDrillScrew(FDS)•ResistanceSpotWelding•Laserwelding•Clinch•Frictionspinwelding

•EvaluatingdifferentjoiningmethodsusedinF150toidentifythemostsuitableonefordifferentmaterialsalloys:

•5000seriesaluminum•6000seriesaluminum•6000seriesaluminumpostformheattreat(PFHT)•Steel

•Comparingthemethodsagainstthedesireddesignspecification,functionalandmanufacturingrequirementstolearnhowthebestonewasselectedforhighvolumeBIWproduction

Mark Keller, Manager of Truck Body Structures and Closures Department, FordLeon Kaunitz, Lightweight/Aluminum Body Structure Technical Specialist, FordMichael Danyo, Aluminum Technology Launch Supervisor, Ford


10.00 Morning Refreshments In Exhibition Showcase Area

CASE STUDY: FULL ALUMINUM BODY APPLICATION

10.30 Determining Optimal Technology Selection Methods When Developing A Full Aluminum Body: Defining The Most Cost Effective Manufacturing Processes To Achieve Full Vehicle Structure Optimization

•ProvidinganoverviewoftheGeely’snewenergysourcesvehicle(PEV)tounderstandwhyaluminumwaschosenfortheentirebodystructure

•SharingtherationalebehindlaunchingGeely’snewenergyresourcesvehicleplatform(AMA)andwhatitmeansforthefutureoftheelectricalvehicleweighttargets

•ReviewingthealuminumbodyapplicationinPEVindetailstoidentifythemainchallengesbeingfaced:

•Addressingthedesignchallengesbasedontheextrudedaluminumprofilealongsidepresshardeningsteel(PHS)andcompositematerials(closure)

•Reviewingtheselectionofmanufacturingmethod(press,extrusion)andjoiningtechniques(welding,adhesivejoiningandriveting)foraluminumenginehoodandfrontbumpertohighlightthereasonfortheiradoption

•Showcasinghowthealuminumbodystructureapplication’sfeasibilityanalysishasbeenperformedforthemanufacturingprocessessuchasstamping,paintingandjoiningtoachieveaccuratemanufacturingcostprojection

•Examininghowthechallenges(tooldesign,automationofthepressconveysystemandselectionofjoiningtechniques)forthealuminumbodyapplicationatGeely’sPEVweresuccessfullyovercome

Fei Xiong, Technology Director of Material Engineering R&D Centre, Geely


MULTI-MATERIAL JOININGAssessing Joining Methods For Mixed Materials With Respect

To The Quantifiable Parameters To Extract Practical Benefit For The Assembly Line

CASE STUDY: JOINING NEW GENERATION UHSS

11.10 Learning How New Generation Steels Are Being Introduced Into Body Structures To Guide The Selection Of Cost Efficient High Volume Joining Techniques

•Mappingthethermalpropertiesofnewsteelstoanalyzetheirimpactonthestampingprocessingandjoiningmethods

•PressHardenedSteel•Generation3Steel•BoronSteel

•ExamininghowtheOEMintegratedthisknowledgeintoahighvolumeproductioncyclesystemcosteffectively

•Assessingthecapabilityofhighstrengthsteelstoadheredespitesurfacecontaminantstodeterminehowitimpactsjointstrengthandtheextenttowhichlubricantsmaybeneeded

•Assessingthelongtermperformanceofdifferentjointsofnewsteeltypestodetermineoptimalpracticeforintegrationofthematerialsintostructuralandnon-structuralcomponentsofthecar

•EvaluatingopportunitiesforcostreductionwiththeuseoffastenersthatcanpierceandclinchnewgenerationUHSSandotheradvancedmaterialswhilebeingeffectivelyintroducedintotheautomotivemanufacturingprocesses

Craig Cowan, President, RB&W


JOINING ALUMINUM WITH CONVENTIONAL STEEL & UHSS

11.50 Reviewing Methods For Joining Aluminum With Conventional And New Grade Steels To Determine Which Technology Is The Most Effective: Cost, Corrosion Risk And Volume Capability

•ResistanceSpotWelding,FrictionStirWelding&MagneticPulseJoining

•Reviewinghoweachjoiningtechniqueinteractswithmaterialmeltingpoint,thermalconductivityandthermalexpansiontopredictjointperformancewitheachtechnologyandmaterialcombination

•Identifyingwhichtechnologyhasproventobethemosteffectivewhenjoiningdifferentalloysofaluminum

•Assessingthecorrosionrisksonjointsmadeusingresistancespotandfrictionstirweldingtodeterminewhichhasthemostpotentialinsavingcorrosionmitigationcosts

•Comparingthelongevityoftheperformanceofjointsusingeachtechnologytoensurethesafetyofthejointsthroughoutthelifeofthevehicle

•Clinching,ClinchRivet,PunchRivet,VarioPointClinching,SpecialInsertionFasteners

•Explaininghoweachjoiningprocessworksandreviewingthematerialsandtheirthicknessestoidentifythebestprocessforeachtype

•Discussjoiningdissimilarmaterialswithadhesiveincombinationswiththesejoiningtechnologiestoevaluatetheireffectivenessintermsofperformance

•Presentingcurrentapplicationsandhighlightingtheadvantagesandlimitationsofeachprocess

Troy Waldherr, Sales Manager, TOX Pressotechnik-North America


ALUMINUM: LASER WELDING FOCUS

12.30 Examining How An OEM Achieved High Volume Mixed Material Aluminum Joints In Structural and Non-Structural Parts Using Laser Welding To Draw Transferrable Lessons On Technology Selection

•Assessingthemechanicalandheatspotperformanceofaluminumduringlaserweldingwhenappliedinstructuralbodypartsandclosuresinrelationtofatiguelimits,humidityandtemperature

•Learningthestrategyappliedtoadjusttheassemblylinestospeeduptheproductionprocess,maximizeefficiencyandenablehighvolumealuminumapplication

•Hearingacasestudyontheuseoflaserweldingforaluminumbodyandclosurestodeterminewhereinthevehiclethetechnologyismostsuitable

•AssessingfunctionalityofthelaserweldingtechniquetomaximizetheperformanceparametersofAl-Aljointintermsofstrengthintheheataffectedzone

•Understandingalloybehavioranditsimplicationontheweldperformanceduringandafterthetreatmenttodrawlessonsonwhichtechnologyworksbest


1.10 Lunch In Exhibition Showcase Area

MAGNESIUM JOINING

2.10 Identifying Which Technologies Can Be Used To Join Magnesium Without Causing Corrosion To Determine The Potential Of Using It In High Volume Vehicle Production

•Assessingthefeasibilityofusingdifferentjoiningprocessesformagnesiumbasedoncompatibilitywithitsdifferentmechanicalpropertiesandresultingperformanceofthejoint

•Analyzingwhichfactorstoconsiderwhenjoiningmagnesiumwithothermaterialstoaiddecisionsonbonding/joiningtechniques

•Assessinghowresistancespotweldingcanbeusedtomaximizethestrengthandperformanceofmagnesiumjoints

•Examiningthepossibilityofauniquebondforjoiningaluminumandmagnesiumtodelivermaximumbondperformance

•Analyzinghowcanthemethodoffrictionstirweldingbeimprovedtooptimizetheprocessingcycletime


FRICTION STIR WELDING DEVELOPMENTS

2.50 Reviewing The Latest Developments In Multi-Material, Steel And Low-Mg Aluminum Alloy Friction Stir Welding To Compare Joint Performance With Traditional Friction Stir Spot Welding

•Reviewingtheperformanceofthefrictionstirandautogenouslaserweldingmethodsathightravelspeedtodrawthecoldformabilitycomparisonfor:

•Low-magnesiumaluminumalloy•Multi-materialjoint•Hybridjoint

•Assessingthelatestadvancementsinaluminumtosteeljoiningusingfrictionstirwelding,wherethepintooldoesnotenterintothesubstrate,toevaluatethepossibilityofitswideradoption

•Analyzinghybridjoiningusingfrictionstirweldinganda‘flow-in’techniqueinAl-AlandAl-Steeltounderstandhowthejointperformanceisbeingincreased

•Drawingcomparisonsbetweenfrictionstirpatternspottechniqueathighplungeratetotraditionalstirspotweldingtoidentifythebestmethodintermsofjointperformance

Francois Nadeau, Technical Leader, Aluminum Assembling Technologies, National Research Council Canada



Concept directly in line with challenges I face everyday. Great to hear other OEMs/Tiers speaking about these issues

Advanced Materials Research, Honda R&D Americas

Good combination of OEM and Suppliers

Chief: Body In White, Ferrari S.P.A

MIXED MATERIAL BONDING & BOLTING

3.30 Appraising The Latest Advancements In Mixed Material Joining And Bonding And Measuring The Results Against The Desired Design Indicators To Determine Which Has Been Proven The Most Effective

•Evaluatingthemixedmaterialjoiningtechniquesthatwerecomparedfortheirstaticanddynamicperformanceandfailuremodestodeterminewhichwouldyieldthehighestperformingjoint:

•Bonded-onlymixedmaterialjoints•Bolted-onlymixedmaterialjoints•Hybridbonded-and-boltedmulti-materialjoints

•Performance:Analyzingtheperformanceresultsobtainedfromjoiningandbondingaluminum,magnesiumandplasticsbasedonthesetdesigncriteriatocomparethesuitabilityofdifferenttechniques

•Evaluatingthebehaviorofthejointsbasedontheenvironmentalconditionstowhichtheyhavebeenexposedto:

•Cyclicheat•Humidity•Saltspraycorrosion

•NanoparticleEnrichment–Adhesive:Presentingthepreliminarydataonnanoparticleenrichmentofbondingadhesivetoevaluateitsfurtherwideadoptioninscalehighvolumevehiclemanufacturing

Dr. Sayed A. Nassar, Founding Director, Fastening and Joining Research Institute (FAJRI)


4.10 Afternoon Refreshments In Exhibition Showcase Area

Day 1Tuesday April 14, 2015


Continued...

UPCOMING TECHNOLOGICAL ADVANCES AND THE NEXT STEPS IN LIGHTWEIGHTING

Examining The Very Latest Joining And Forming Innovations That Could Revolutionize Costs And Discussing What Needs Done As An Industry To Reduce Costs In The Next 3 Years

LAB BASED INNOVATIONS IN THE PIPELINE: INTERACTIVE PANEL DISCUSSION

4.40 Exploring The Potential Of Brand New Joining And Forming Techniques Still In The Testing Phase That Are Set To Enable Mass Production Within The Next 3 Years

•Assessingwhatbrandnewtechnologicaladvancescurrentlystillinthetestingphase,couldhelptoindustrializelightweightjoiningandforminginthenext3years

•ScrutinizingopportunitiesinthenextgenerationofhotstampingprocessesforUHSSstoidentifythepotentialoffurtherscalinguptheoutputatthelowestcost

•Exploringopportunitiestochangevehicledesignandadjustmanufacturingprocesstotakeafurther10-15kgoutofthevehicleweightwithminimuminvestmentrequired

•Examiningwhichracingandmotor-sportsjoiningtechniquesarebeingtestedforuseandcanbepotentiallyadoptedintheconsumervehicleindustry

Pete Edwards, R&D Leader for Joining, Honda Engineering North America, Inc.Dr. Richard J. Gerth, Ground Systems Survivability, Tank Automotive Research, Development, and Engineering Center, US Army - RDECOMLawrence E. Brown, Executive Director, ALMMII


NEXT STEPS: INTERACTIVE PANEL DISCUSSION

5.20 Determining What The Automotive Industry Still Needs To Achieve To Enable Lower Cost High Volume Lightweight Vehicle Production In The Context Of What Has Already Been Done

•ThoughtsOnWhat’sNext:HearingthethoughtsofthepanelistsonwhattheR&Dfocusshouldbeoverthenext3yearsinordertomakesubstantialprogressincostreduction

•Recycling:Howcanrecyclingprocessesbedesignedinawaytomaximizevaluereturnonwasteandminimizescrap

•Standardization:Howcanthemanufacturingcapabilitiesofplantsindifferentgloballocationsbestandardizedtotakefulladvantageoftheeconomyofscale

•Maintenance:Examiningwhatimprovementstotheequipmentmaintenanceprocesscanbemadetominimizethedowntimerelatedtothefailureofcertainparts

Surender Maddela, Senior Research & Development Engineer, Materials Engineering, Nissan Motor Corporation


6.00 Chair’s Closing Remarks

6.10 – 7.00 Networking Drinks Reception In Exhibition Showcase Area

Great start to a communal effort to establish and promote manufacturing considerations related to lightweight materials

Applications Engineer, Mills Sales

Diverse OEM viewpoints

Welding Technical Expert, Ford

A culmination of thought leaders from OEMs, suppliers and innovators

COO, Local Motors

•Cracking:Analyzingwhichmethodsarerightformaterialssusceptibletocracking

•ThermalDiffusivity,Conductivity&MeltingTemperatures:Identifyingthermalpropertiesofnewmaterialsandgradestobeabletopredicttheirperformanceduringandafterjoiningoccurs

•Assessingtheviabilityofintroducingindustry-widestandardsfornewandexistinglightweightmaterialstohelpbringconsistencytojoiningandformingbestpractices

Dr. P. K. Mallick, Director of Center for Lightweighting Automotive Materials and Processing (CLAMP), University of Michigan-Dearborn


CORROSION PROTECTION

2.10 Environmental Durability Of Aluminum Adhesive Joints And Corrosion-Sensitive Aluminum Alloys: One More Step Toward A More Reliable Laboratory Evaluation Of In-Service Performance

•Establishingcycliccorrosiontestsandelectrochemicalprocedurestomimictheperformanceofcoatedcorrosionsensitivealuminumalloysexposedtoharshroadconditions

•Developingnon-destructiveinspectiontechniquesforinsitumonitoringofadhesivejointhealthexposedtoroadconditionsduringthedevelopmentstepofsurfacepretreatments

•Determininglaboratorytestingproceduresforreliablein-serviceperformanceofadhesivejoints

•Acceleratedevaluationofcorrosionassistedfatigueandstresscorrosioncrackingbehaviorofhighstrengthandcorrosionsensitivealuminumalloys

Danick Gallant, Research Agent, National Research Council Canada


2.50 Afternoon Refreshments In Exhibition Showcase Area

INFRASTRUCTRE AND LIGHTWEIGHT TECHNOLOGY INTEGRATION

Assessing How Existing Infrastructure Can Be Most Cost Effectively Adjusted To Optimize Lightweight Vehicle Output

And Enable Mass Production

OPTIMIZING EXISTING PLANT INFRASTRUCTURE: AUTOMATION

3.20 Hearing How OEMs Are Automating Typically Manual Processes To Improve Cycle Times And Reduce Costs Of Lightweight Vehicle Production

•Assessinghowjointscanbebestdesignedforautomationtomaximizetheapplicabilityofautomationtechnologies

•HearingtheamountoftimethatwassavedperjointwhentheOEMswitchedtoautomationtohelpjustifythebusinesscasefornewapplications

•Understandinginwhichareasofthemanufacturingprocessautomationhasprovenmostsuccessfultodeterminewhichprocessescouldbenefitmostfromitsapplication


4.00 Chair’s Closing Remarks And End Of Conference

Day 2Wednesday April 15, 2015


8.30 Chair’s Opening Remarks

HIGH VOLUME FORMING Examining The Forming And Processing Technologies That Are Being Used For New UHSS, Carbon Fiber And Other

Advanced Composites To Identify The Most Sound Method To Use In High Volume Production

PROCESSING CARBON FIBRE COMPOSITES

8.40 Understanding Mechanical Properties And The Processing Issues Related to The Advanced Composites To Evaluate Feasibility Of Use In High Volume Lightweight Manufacturing

•LearningtheprosandconsofdifferentformingoptionsforCFC(closedvs.openforming,orientationlayout)toassesswhethermassproductionofCFCunitswillbeviableinthefuture

•InvestigatingwaystospeeduptheprocessofproducingandmanufacturingCFCcomponentswhileensuringthequalityandsolidityoftheunit

•Analyzingwaystoprocessadvancedcompositeswhilemaintainingstrengthofthejointandpartperformancerequirements

•Assessingthefinishingperformance,paintability,mechanicalpropertiesandappearanceofadvancedcompositesandtheirabilitytobebondedandfastened

•UnderstandingtheroleofthesupplierinspeedinguptheproductionofCFC,allowingOEMstosecuringwiderscaleavailability

Mark Voss, Engineering Group Manager, Body Advanced Technical Works, GM


9.20 Morning Refreshments In Exhibition Showcase Area

ADVANCED CARBON FIBER COMPOSITE FORMING

9.50 Understanding Tried And Tested Ways Of Forming Carbon Fiber To Justify The Business Case For Its Application In Automotive Vehicle Production: RAD’S Car Beast Case Study

•Evaluatingvariousmethodstomakecarbonfibertounderstandhowitsusecanbejustifiedasavalueaddedinregardstotheweight/performanceratio

•Comparingcostsandbenefitsofthevariousmethodsforcarbonfiberproductiontoevaluatetheprosandconsassociatewiththeiruseincarbody

•Wetlayupusingvinylesterorepoxyresin•Wetlayupwithvacuumbaggingusingvinylesterorepoxy

resin•Pre-regcarbonheatedinautoclave

•EvaluatingwaystocosteffectivelymanufacturecarbonfiberpartsyetmaintainstrengthwiththebestprovenoneforRADbeingwetlayupwithouterandinnerpanel

•Investigatinghowtodesigncarbonfiberelementstohelpobtainandretainpartsstrength:

•Showinghowtolineupwavesinthemosteffectivemanner

•Whatistheoptimalnumberoflayersrequired•Whywetlayupusingepoxyisbeingselectedaspreferred

method•Howhavinginnerandouterpanelhelpstoobtain

maximumstrength Kam Hosn, Co-Founder, RAD Cars


JOINING CFC

10.30 Evaluating The Performance Of Techniques For Joining CFC Parts In Low to Medium Level Production In Relation To Speed Of Production, Cost and Cracking Risk

•DebatinghowtojoinlowtomediumvolumeofCFCunitsinasinglefacilitywhilecontrollingthequalityoftheunittodrawtransferrablelessonsforotherOEMs

•ExploringdifferentassemblystrategiesandtechniquesthatcouldbeadoptedforCFCtoallowtheassemblyoutputtoreachmediumvolumeofoutputatthereasonablecost


ADDITIVE MANUFACTURING

11.10 Assessing the Potential of Direct Metal Laser Sintering (DMLS) To Reduce The Costs Of Lightweight Vehicle Components

•DMLSvs.TraditionalMetalForming:ExaminingadvantagesanddisadvantagesofDMLSvs.currentmetalformingprocessestounderstandthemostappropriatecriteriatoconsiderwhendesigningpartsforvolumeproductionincluding:

•Cost:AssessingthecostperDMLS-producedpartinbothmediumandhighvolumecomponentproductiontodeterminewhetherthismethodiseconomicallyfeasibleforglobalcompanies

•Volume:AssessinghowmanypartsperdaycanbeformedtodeterminethespeedcapabilityofDMLSprocessandwhetheritcansupporthighvolumeproduction

•Expandingtheboundaries:Identifyingnewerpotentialusesforadditivemanufacturingoflightweightparts,beyondthetypicalapplications

•NewAdvances:Evaluatingworkbeingconductedtoimprovethecapabilityofadditivemanufacturinginsupportinghighvolumeapplicationswithconsiderationstocostsandcycletime

Gregory E. Peterson, Senior Technology Specialist, Lotus Engineering


PROCESSING NEW GENERATION STEELS

11.50 Examining The Behavior Of New 3rd Generation Advanced And Ultra High Strength Steels During And Post-Forming To Determine Which Method Has The Lowest Costs Per Part

•CrackingPropensity:Analyzingtheperformanceofnewsteelsvs.conventionalsteelduringvariousformingprocessestomaptheirformability,propensitiestocrackingandthermaldiffusivity

•Costs:Comparingthecostandspeedofformingnewsteels(Gen3AdvancedandUHSS,TWIP)toidentifywhichareoptimalintermsofrequiredperformance

•MeltingTemperatures:Comparingthemeltingtemperaturesofthesteelstounderstandtheimpactsofusingthemindifferentpartsofthevehicle

•HeatBalance:Understandingtheperformanceofboronsteelpartsafterthehotstampingprocesshasbeenappliedtoderivemethodsforimprovingcontroloverthermalstressconcentration


12.30 Lunch In Exhibition Showcase Area

MATERIAL CHARACTERIZATION & CORROSION MITIGATION

Analyzing How The Properties Of New Grades Of Lightweight Materials And Composites Define The Selection Of Optimal Joining And Forming Techniques And What Are The Latest

Advancements In Corrosion Mitigation

MATERIAL CHARACTERIZATION: MANUFACTURING IMPLICATIONS

1.30 Evaluating The Properties Of The New Grades Of UHSS, Aluminum And Composites To Determine Their Influence On The Selection Of Joining And Forming Technologies

•Definingthepropertiesofthenewlightweightmaterialstodrawthecomparisonoftheirperformanceduringjoiningandprocessingagainstthemajorcriteria:

•TensileStrength,Ductility,SpringBack:Examiningwhichjoiningtechniquesaremostappropriateforprocessingmaterialswithdifferentductility,strengthandspringback

•GalvanicCorrosion&Fatigue:ExamininghowOEMsareusingdataoncorrosionandfatiguetoaidtheselectionofjoiningtechniquestobecapableofhighvolumeproduction

HIGH VOLUME FORMING & INTEGRATING NEW LIGHTWEIGHT TECHNOLOGIES INTO THE PLANT

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The conference is being organized by American Business Conferences, a division of London Business Conferences Ltd, a limited liability company formed under English company law and registered in the UK no. 5090859.Cancellations received 30 days prior to the start of the event will be eligible for a refund less $150 administration fee, after this point no refund will be given. Cancellations must be made in writing, if you are unable to attend you may nominate a colleague to attend in your place at no additional cost.Receipt of this registration form, inclusive or exclusive of payment constitutes formal agreement to attend and acceptance of the terms and conditions stated.All outstanding fees must be paid within our standard payment period of 7 days. Any outstanding invoices will remain valid should cancellation of attendance be received outside of the aforementioned cancellation period.*If you are claiming the early booking discount this may not be used in conjunction with other discounts advertised elsewhere. All discount codes and offers must be claimed at

the time of registration.American Business Conferences reserves the right to alter or cancel the speakers or program.American Business Conferences reserve the right to refuse admission.We would like to keep you informed of other American Business Conferences products and services. This will be carried out in accordance with the Data Protection Act. Please write to the Head of Marketing, American Business Conferences at the address below if you specifically do not want to receive this information.American Business Conferences. City Center One. 800 Town & Country Blvd. Suite 300. Houston. Texas. 77024American Business Conferences will not accept liability for any individual transport delays and in such circumstances the normal cancellation restrictions apply.American Business Conferences is a Division of London Business Conferences Limited, Registered in England No. 5090859 EIN. no: 98-0514924

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SPECIAL OFFER

Payment must be received in full prior to the event.

*Option 1. CREDIT CARD Please charge my * VISA * AMERICAN EXPRESS * MASTERCARD

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How To Finalize Your Registration

*Option 2. INVOICE An invoice containing payment instructions will be sent electronically upon receipt of the completed registration form.

Super Early Booking Discount Early Booking Discount Standard Rate

Book And Pay By Friday February 27 Book And Pay By Friday March 13 From March 14

2 Day Conference Pass * $1399 USD SAVE $400 * $1599 USD SAVE $200 * $1799 USD

Exclusive Vehicle Manufacturer 2 Day Conference Pass * $800 USD SAVE $200 * $900 USD SAVE $100 * $1000 USD

Add Audio & Video Recordings * $650 USD

Now that your details are completed please send your registration form to our Customer Service Team using one of the following options:Option 1. Email: [email protected] 2. Fax: (1) 800 714 1359

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Should you have any enquiries or if you would like to request more information contact our friendly Customer Service Team on (1) 800 721 3915

Add Live Streaming Exclusive Vehicle Manufacturers Rate * $499 USD Standard Rate * $1099 USD

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