EVENT PARTNER

Semblex

ALUMINUM EXTRUSION PARTNER

hydro

ADAPTIVE DFS PARTNER

Deprag

AUTOMOTIVE STEEL PARTNERS

US Steel

LASER AUTOMATED SOLUTIONS PARTNERS

Trumpf

CO-SPONSORS

TOX Arplas impression

NETWORKING BREAK SPONSORS

stanley

2018 Conference Agenda

Day 1 - 21st February 2018

Assessing The Future Of Joining And Manufacturing Technologies For EV/Hybrid Vehicles Multi-Material Joining Strategies For: Aluminum, Next-Generation Steel And Composites

08:50 Chair Opening Remarks

DAY 1 Chair: Jim Erhardt, President,Rifast Systems LLC

OPENING KEYNOTE PANEL SESSION

09:00 Assessing The Structural Requirements Of Electric Vehicle BIW's And The Impact On Joining, Forming And Manufacturing Technologies Of The Future

  • How does vehicle electrification impact overall body engineering; how will it transform the joining and manufacturing currently available?
  • What joining technologies are currently being utilized for EV vehicles?
  • How the production of EV vehicle will impact the overall existing manufacturing assembly?
  • What are the advancements in body engineering in new series built vehicles: what is the future?

Panelist: Elie Tohme, Director of Body Engineering, Karma Automotive

Panelist: Antonio Mercado, BIW Process Engineering Manager, Faraday Future

09:40 Question And Answer Session

09:50 RESERVED FOR DEPRAG

10:20 Question And Answer Session

10:30 Refreshments Network Session - SPONSORED BY DEPRAG

CASE STUDY: JOINING DISSIMILAR MATERIALS FOR EV BATTERY INTEGRATION IN NEW MODEL VEHICLE STRUCTURE

11:00 Mounting And Integrating Battery Packs Into Lightweight Body Structures

  • Evaluation of different joining techniques and manufacturing technologies for mounting and integrating battery pack casing
  • Structural design features and enhanced joint performance to safeguard battery packs integration
  • Improved CAE process, simulation and prediction

Dr. Salman Khan, Senior CAE Lead, Faraday Future

11:30 Question and Answer Session

11:40 RESERVED FOR SEMBLEX

12:10 Question and Answer Session

12:20 Networking Lunch Session - SPONSORED BY SEMBLEX

INNOVATION: METHODOLOGY FOR ALUMINUM TO STEEL STRUCTURES

13:30 Solutions To Resistance Spot Welding Of AHSS & Novel Process For Welding Aluminum To Steel

  • Resistance spot weld micro-structure and properties characterization of AHSS
  • Resistance spot welding of Hot-stamped boron steel with Zn and Al-Si coatings
  • Resistance spot welding of complex steel stack-ups
  • Development of new method for welding aluminum to steel

Menachem Kimchi,Advanced Materials Joining, Ohio State University

14:00 Question and Answer Session

MATERIAL JOINING

14:10 Material Joining Rsearch & Development At Oak Ridge National Laboratory

Feng Zhili, Group Leader Processing & Joining, Oak Ridge National Laboratory

14:40 Question and Answer Session

LASER WELDING FOR DISSIMILAR MATERIAL JOINING

14:50 Laser Welding Between Steel And Ductile Iron Dissimilar Materials

  • Laser Welding SAE D5506 ductile iron to SAE 5120M steel for front wheel drive differential carrier.
  • 360 degree circular weld and effect of weld overlap quality on welding defects.
  • Effect of weld geometries and welding parameters on weld cracking.
  • Weld quality requirement.

Huaxin Li, Technical Specialist -Ferrous Matl & Welding, General Motors

15:20 Question and Answer Session

FASTENERS FOR AHSS

15:30 Clinch Nut Applications For Advanced High Strength Steels (Rm > 800 Mpa)

  • Development of Class 10 fasteners for installation in AHSS (800 MPa and beyond)
  • Clinched joint characteristics:

                 - Class 10 joint for assembly
                 - Minimal deformation of stamping material
                 - ZERO cracking on the fastener features during clinching process

Viral Varshney, Director of Engineering, Rifast LLC

16:00 Question and Answer Session

16:10 Refreshments Network Session - SPONSORSED BY RIFAST

CASE STUDY: RESISTANCE SPOT WELDING

16:40 Resistance Spot Welding and Structural Adhesive Applications in a Low Throughput/Medium Level of Automation Body Line

  • Resistance spot welding (RSW) process control and verification practices used in a low throughput/medium level of automation body line.
  • Structural adhesive application process control, and how to improve & decrease valuation for the application of adhesive.
  • Understand the best practices of adhesive applications in a non robotic application

Mohamad Elkafafay, Operational Excellence Specialist, GM

17:00 Question and Answer Session

MULTI-MATERIAL JOINING PROCESSES

17:10 Joining of Similar and Dissimilar Engineered Materials

  • TOX joining of aluminum
  • TOX joining of high strength steels
  • Other joining processes supported by TOX

Troy Waldherr, North American Sales Manager, Tox Pressotechnik

17:30 Question and Answer Session

CASE STUDY: BIW ADHESIVE BONDING FOR BODY ENGINEERING

17:40 Successfully Joining Composites To Aluminum Using Structural Adhesive: To Achieve Flexibility And Thicker Bond Line

  • The performance and durability of structural adhesive bonded joints
  • Evaluate the performance of adhesive bonding joints after it goes through hot and cold cycle
  • How to match / compensate for differences in coefficient of thermal expansion between metal and composite parts
  • Improve the performance of structural adhesive joints in a high impact scenario
  • Improve prediction simulation of adhesive joints to understand crashworthiness and safety

Fardi Haddadi, Process Engineering Specialist, Faraday Future

18:10 Question and Answer Session

SUPPLIER CASE STUDY: ROBOT ADHESIVE DISPENSING SYSTEM

18:20 Discover Advances In Robot Dispensing In The Assembly Line To Enhance Adhesive Performance

  • Determine the latest advances in assembly line robots
  • Discover what quality check systems are in place following the robot application of adhesive bonds to ensure correct volume is applied

18:40 Question and Answer Session

ADHESIVE INNOVATION

18:50 Multi-Substrate Adhesives for Automotive Production - US Market.

Gino Mariani, Marketing - Automotive & Metals Industries, Henkel Adhesive Technologies

AEROSPACE FOCUS: MECHANICAL AND ADHESIVE JOINING

19:00 Question and Answer Session

19:10 Day One Conclusion Remarks From Jim Erhardt, President, Rifast Systems LLC

19:15 - 20:15 Networking Drinks Reception In Exhibition Area Sponsored By Rifast Systems LLC

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Day 2 - 22nd February 2018

Discussing Technologies And Methodologies To Mitigate Galvanic Corrosion; Thermal Expansion Challenges And Optimise Manufacturing Of Lightweight Material Body Structures

08:30 Chair Opening Remarks - Auto/Steel Partnership introduction  

The chair will present the latest trends of in the auto/steel partnership and give a break down on the latest industry intelligence associated with competitive lightweight steel solutions for current and future requirements of automotive OEMs

Chair: John Catterall, Executive Director, Auto/Steel Partnership

AUTOMOTIVE STEEL SUPPLIER

8.35 Steel Still Relevant? More than Every Say The Suppliers. The Role That Steel Could Play In Innovative New Vehicle Design

Panelist: John Catterall, Executive Director,Auto/Steel Partnership

Panelist: United States Steel

Panelist: Dr. P. K. Rastogi, Principal Engineer, AK Steel, Research & Innovation, AK Steel

Panelist: Scott M. Stone, Section Leader - Global Technology Coordinator Automotive Product Applications, ArcelorMittal USA

Panelist: Jonas Adolfsson, Business Development Automotive, SSAB / Docol

Panelist: Steel Market Development Institute

DEPARTMENT OF ENERGY AUTOMOTIVE INITIATIVES

09:20 Introduction On Material Joining Initiatives And Programs At Department Of Energy

Feng Zhili, Group Leader Processing & Joining, Oak Ridge National Laboratory

09:40 Question and Answer Session

STRUCTURAL ADHESIVE CORROSION

09:30 Strategies And Technologies Currently Available To Eliminate Galvanic Corrosion For Metallic Body Structure

  • Assess the adhesive bonding performance between composite and metal
  • How to avoid water properties from entering the adhesive joints during application
  • Assess the best approach for two or three dissimilar materials joining to avoid galvanic corrosion

Michael Danyo, Technical Specialist - Aluminum Structures, Ford Motor Company

09:50 Question and Answer Session

ALUMINIUM JOINING APPLICATION

10:00 Joining Of Aluminum Extrusions In Automotive Applications

  • Structural joining methods in BIW components
  • E-mobility: challenges for joining techniques
  • Battery boxes, el. motor casings, enclosures, electric cables
  • Joining dissimilar materials:
  • Desired combinations
  • Current and Prospective technologies

David A. Lukasak,Director Innovation & Technology,Hydro Extruded Solutions North America

10:10 Question and Answer Session

ADHESIVE INNOVATIVE PRODUCTS

10:40 Automated Stud Gluing Without Adhesive Application 

  • Motivation behind Stud Gluing System (SGS)
  • Process Benefits and Bonding Performance
  • Next Generation SG

Dr. Sascha Gramsch-Kempkes, R&D Team Leader - Adhesive Technologies, Stanley Engineered Fastening

10:50 Refreshments Network Session - SPONSORSED BY STANLEY ENGINEERED PRODUCTS

Focus A: Magnesium Manufacturing Techniques

CASE STUDY: DIE CAST MAGNESIUM

11:20 Magnesium Sheets Panels Forming And Discover Whether It Is Viable For Mass Production

  • Advancements in the current stamping techniques available for magnesium sheets
  • Evaluate the challenges involved in manufacturing magnesium components and discover potential solutions
  • Understand how to form magnesium components for high volume production
  • Examine the ductility of magnesium components in overall vehicle structure
  • How to join magnesium components to a steel or AHSS part

Fadi AbuFarha, Assistant Proffesor, Clemson University

11:50 Question and Answer Session

Focus B: UHSS & AHSS -Stamping Methodologies And Improve Springback Prediction

CASE STUDY: HOT STAMPING FOR UHSS HIGH VOLUME VEHICLE PRODUCTION

12:00 Improve Methodology For UHSS High Volume Hot Stamping Production

*    How to streamline hot stamping process to reduce overall cycle time
*    What type of high strength steel is more suited for stamping to achieve better elongation
*    How to process a reduction in gradient on hot forming high strength steel to achieve less than 0.7 gradient

Abhay Vanhakar, Senior Site Manager - Supplier Technical Assistance, Ford Motors   

12:20 Question and Answer Session

CAN STEEL IMPROVE THE AFFORDABILITY OF ELECTRIC CARS?

12.30 How AHSS can contribute to reducing the weight of complex components, a crucial element of improving driving range for EV batteries. The presentation will also examine further AHSS benefits to EV manufacturing, such as strong but lightweight battery protection and affordable cost levels.

*    What role do advanced lightweight materials play in future cars?
*    How can materials affect BIW stiffness in BEVs and still being a part of global and battery safety?
*    And will the EVs of the future only use expensive materials?

Jonas Adolfsson, Global Automotive Business Development, SSAB / DOCOL
12:50 Question and Answer Session

13:00 Networking Lunch In Exhibition Hall SPONSORSED BY HYDRO EXTRUDED SOLUTIONS NORTH AMERICA

CASE STUDY: UHSS MILD STAMPING AND MITIGATION OF SPRINGBACK

14:00 How To Achieve Dimensional Quality Without The Challenge Of Springback

*    What technologies are currently available improve prediction of final UHSS component geometry?
*    What tools are required to compensate springback effect?
*    What are the current methods or strategies in mitigating springback in forming high strength steel?

RESERVED FOR GM

14:20 Question and Answer Session

CASE STUDY: HOT STAMPING PROCESS PARAMETER

14:30 Influence of Hot Stamping Process Parameters on Downstream Manufacturing Processes

  • Understanding which available parameters for optimizing hot stamping quality of Ultra High Strength Steel components
  • Discover the complexity of challenge for production and how up and down stream heating processing can affect stamping, joining and corrosion protection
  • how the heating process parameters affect the coating development and subsequent resistance spot weldability of homogenous stackups
  • Empirical and analytical model results on Al-Si coated Boron steels

Raj Sohmshetty, Group Leader - Advanced Steel Technology Manufacturing Research Department, Ford Motors

14:50 Question and Answer Session

15:00 Networking Break In Exhibition Hall SPONSORSED BY HYDRO EXTRUDED SOLUTIONS NORTH AMERICA

Focus C: Composites - Gain Confidence In The Manufacturing Of Next Stage Of Lightweight Materials To Stay One Step Ahead

ENERGY SAVINGS WITH RESISTANCE WELDING (RPW)

15.30 Resistance Projection Welding (RPW) is a welding technology that uses a rectangular projection (dimple) formed in one of the mating parts to create the electrical connection and focus the welding energy in a concentrated area. 

    *    33% of the force
    *    less than 20% of the weld duration
    *    up to 200% more current

Marc Auger, Director of Sales, Arplas USA LLC.

15:45 Question and Answer Session

CASE STUDY: 3D MANUFACTURING

15:55 Assess The Current Trends In 3D Metal Laser Sintering

  • Understand how 3D metal laser sintering can improve current manufacturing scenario for lightweight material components
  • Review challenges and requirements of 3D MLS for large scale volume manufacturing

Dr Paul J Wolcott, Applications Engineer - Additive Manufacturing, General Motors

16:15 Question and Answer Session

Focus E: Aluminum - Improve Aluminum Forming Efficiencies Without Increasing Overall Infrastructure

CASE STUDY: ALUMINUM STAMPING

16:25 Discover How To Improve Aluminum Stamping Process For A Better Quality Of Finished Product

  • Analyzing the current manufacturing trends and processes for aluminum 5xxx, 6xxx and 7xxx series
  • Understand how to maintain a quality finish for aluminum and avoiding burr material getting into the die

Speaker: Impression Technologies

16:45 Question and Answer Session

ALUMINUM JOINING APPLICATION

16:55 Joining Of Aluminum Extrusions In Automotive Applications

  • Structural joining methods in BIW components
  • E-mobility: challenges for joining techniques
  • Battery boxes, el. motor casings, enclosures, electric cables
  • Joining dissimilar materials:
  • Desired combinations
  • Current and Prospective technologies

David A. Lukasak, Director Innovation & Technology, Hydro Extruded Solutions North America

17:15 Question And Answer Session

17:25 HYDRO EXTRUDED SOLUTIONS NORTH AMERICA Concluding Remarks + Apple TV Draw

17:35 - 18:35 Networking Drinks Reception In Exhibition Area SPONSORED BY HYDRO EXTRUDED SOLUTIONS NORTH AMERICA

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