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
Register By FridayFebruary 27, 2015
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
Register By FridayFebruary 27, 2015
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
www.global-lightweight-vehicle-manufacturing.com (1) 800 721 3915 [email protected]
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
9.50 Question & Answer Session
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
11.00 Question & Answer Session
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
11.40 Question & Answer Session
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
12.20 Question & Answer Session
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
1.00 Question & Answer Session
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
2.40 Question & Answer Session
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
3.20 Question & Answer Session
www.global-lightweight-vehicle-manufacturing.com (1) 800 721 3915 [email protected]
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)
4.00 Question & Answer Session
4.10 Afternoon Refreshments In Exhibition Showcase Area
Day 1Tuesday April 14, 2015
www.global-lightweight-vehicle-manufacturing.com (1) 800 721 3915 [email protected]
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
5.10 Question & Answer Session
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
5.50 Question & Answer Session
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
2.00 Question & Answer Session
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
2.40 Question & Answer Session
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
3.50 Question & Answer Session
4.00 Chair’s Closing Remarks And End Of Conference
Day 2Wednesday April 15, 2015
www.global-lightweight-vehicle-manufacturing.com (1) 800 721 3915 [email protected]
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
9.10 Question & Answer Session
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
10.20 Question & Answer Session
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
11.00 Question & Answer Session
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
11.40 Question & Answer Session
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
12.20 Question & Answer Session
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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SAVE UP TO 20%WITH GROUP DISCOUNTSCall for rates: (1) 800 721 3915
Terms & Conditions
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
Expiry date
Security Code / CVV (required)
Signature of card holder
Amount $ USD
Card number
Name on card
Delegate Rates GUESTS ARE RESPONSIBLE FOR THEIR OWN TRAVEL AND ACCOMMODATION ARRANGEMENTS
Payment PLEASE TICK APPROPRIATE BOXES AND COMPLETE DETAILS
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
Enquiries And More Information
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