EVENT PARTNERS

Semblex Henkel summ

EXTRUDED ALUMINUM PARTNER

hydro

ADAPTIVE DFS PARTNER

Deptra

AUTOMOTIVE STEEL PARTNERS

US Steel

COMPONENTS, PRESSES & CUSTOM MACHINERY PARTNER

TOX

CO-SPONSORS

coher nobleclad Huntsman Advanced Materials Caresoft Global MAg

WHO SHOULD ATTEND

Network And Create Opportunities With


  • Local and International OEMs
  • Tier 1 Suppliers
  • Material Suppliers
  • Equipment And Service Suppliers
With The Following Job Titles:

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

  • Body Structures
  • Body In White
  • 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


2019 Summit Agenda

Day One: Tuesday, February 19, 2019

Advances In Mixed-Material Joining And Forming Strategies, Technologies And Manufacturing Processes For High Strength Steels, Aluminum Alloys, Advanced Plastics And Composites

08:00  Coffee and Registration

09:00  Chair's Welcome And Introduction

Dr. Khaled Shahwan, Technology Lead, Composites, Methods & Strategies, Global Innovation & Advanced Development Engineering, Fiat Chrysler Automobiles (FCA)

COST-EFFECTIVE STRATEGIES FOR JOINING OF HIGH STRENGTH STEELS AND ALUMINUM ALLOYS

OPENING PANEL - SENIOR MANUFACTURING AND INNOVATION ENGINEERS

09:10  Impacts Of Migration To EVs And Mixed-Material Body Structures On Joining Technologies And Manufacturing Processes

  • Comparing different methods of joining aluminum to steel in terms of costs and payback  
  • Best practices specifically on joining of new high strength steels and aluminum alloys
  • How to manage the joining process with different coatings and interfacial treatments
  • Achieving a balance between lightweighting, vehicle performance and corrosion performance for EVs

Adam Ballard, Innovation Lead Engineer, Upper Body, Body SMT Innovation Team, General Motors

Antonio Mercado, Advanced Manufacturing Manager, Karma Automotive

Daniel Saltzmann, Staff Engineer - Joining and Materials Specialist, NIO

Hank Bonutti, Advanced Technology Manager, Mahindra NATC

Martin (Marty) McDonnell, Experimenter Mechanical Engineer, Joining and Additive Manufacturing (JAM) Team, Materials Division, TARDEC

James Truskin, Technical Fellow, Advanced Body Architecture, Development Lead, Fiat Chrysler Automobiles (FCA)

Panel Chair: John Catterall, Executive Director, Auto / Steel Partnership (A/SP)

CASE STUDIES

09:50  The Auto/Steel Partnership's (A/SP) Mixed Material Joining Project: Case Study Of Joining An Aluminum Roof Panel To A Steel Body Structure

  • Evaluating multiple mixed material joining technologies for OEM body shops
  • Creating a matrix of strength data for typical load cases
  • Evaluating new technology as it is presented to the project team

Adam Ballard, Innovation Lead Engineer, Upper Body, Body SMT Innovation Team, General Motors

10:15  Joining And Manufacturing New High Strength Steels And Aluminum Alloys - Applying Innovation To Technology, Treatments And Coatings

  • Friction Stir Dovetailing (FSD) - applying innovation and quality enhancements to the joining process
  • Examining the latest transformative technology for joining HSS and aluminum
  • New steel alloys for the lightweighting of vehicle components and assemblies
  • Developments in high strength Gen 3 steels with good formability at the 1000Mpa and 1200Mpa levels
  • Managing springback for improved dimensional control 
  • Dealing with Liquid Metal Embrittlement (LME) and porosity challenges in welding processes

Martin (Marty) McDonnell, Experimenter Mechanical Engineer, Joining and Additive Manufacturing (JAM) Team, Materials Division, TARDEC

10:40  Questions and Discussion       

10:50  Networking Coffee Break In Exhibition Area

11:20 Headline Sponsor Presentation: Innovations In New Fastener Types And Rivets For Joining

  • Aluminum, Carbon Fiber And Steel
  • Developments in new lightweight fastener types and riveting for mixed material structures and reduced vehicle weight
  • Joining aluminum and carbon fiber to each other and to steel
  • Implications for mechanical fastening approaches with the adoption of Industry 4.0, increased automation and automated assembly cells   

Viral Varshney, Director of Engineering, Rifast Systems

11:45 Questions and Discussion

OPTIMIZING STRUCTURAL ADHESIVE USE AND RELATED APPLICATIONS

11:50 Structural Bonding For Battery Electric Vehicles

  • Potential for smart chemistries to enable OEMs to meet lightweighing goals
  • Paving the way for new vehicle structures
  • Using different resins and fibers
  • Structural hybrid solutions for EV battery protection

Brooke Virost, Business Development Manager, Henkel Corp.

Eugene Chung, Business Development Manager, Henkel Corp.

12:15 Questions and Discussion

ROBOTIC TECHNOLOGY, AUTOMATED VISION SYSTEMS AND APPLICATIONS

12:25  Inline Robust 3D Inspection And Process Control Of Bead Dispensing

  • Importance of inline inspection of bead quality with structural adhesives and sealants
  • Utilizing 3D machine vision to inspect complex parts during the manufacturing assembly process to ensure highest quality finished components
  • High speed inline inspection to increase throughput

Zhenhua Huang, General Manager of Americas, Coherix

12:50  Questions and Discussion

13:00  Networking Lunch In Exhibition Area

14:00  Automotive Benchmarking Using X-Ray Scan Technology

  • Complete vehicle architecture and digital mock up (DMU)
  • Modelling of joining techniques and material properties
  • 3D simulation and engineering data comparison in a virtual environment

Samy Panneerselvam, Technical Director, Caresoft Global

14:25  Questions and Discussion

14:30  Developments In Automation For Inspection And Assuring Quality And Dimensional Control In The Body Shop

  • Role for automation, including adaptive tooling, A.I. and 3D vision systems, in ensuring enhanced dimensional control in manufacturing and reducing time to achieve objectives in new production lines
  •  Automated vision systems for optimized joining, assembly and dimensional control
  • Inspecting Class A surfaces visible to the customer with laser scanning at high resolution and high volume rate to provide surface quality validation

George Ghanem, BSME, MBA, 6Sigma MBB, Chief Technology Officer, ProcessChamp

14:55  Questions and Discussion

EMERGING TECHNOLOGIES FOR FASTER, MORE COST-EFFECTIVE, MANUFACTURING PROCESSES

15:00  Innovations In Joining Using Flow Fastening Technology

  • Process overview and adaptive parameterization
  • Advancements in available fasteners
  • Developments in installation equipment

Boris Baeumler, Senior Applications Engineer, DEPRAG

15:25  Questions and Discussion

15:30  Networking Coffee Break In Exhibition Area Sponsored by DEPRAG

16:00  Joining Modern Materials - Mechanically And Electrically

  • Developments in mechanical joining of like and dissimilar materials
  • How mechanically joined material combinations perform as an electrical conductor
  • Benefits of the clinching process over other commonly used joints for electrical conductivity in both low and high amperage applications

Troy Waldherr, North American Sales Manager, TOX-Pressotechnik

16:30  Advancements In Wet Compression Molding (WCM) For High Speed, Mass Production Of Structural Composite Parts

  • Overview of recent advancements in molding techniques and resin systems for achieving faster cycle times, improved surface quality, reduced void content and increased part complexity
  • Benefits of Dynamic Fluid Compression Molding (DFCM) compared to traditional WCM and HP-RTM
  • Description of applications and fabric selections

George Guo, Senior Scientist, Huntsman Advanced Materials

17:00  Disruptive Technologies In Forming And Joining

  • Emerging manufacturing technologies to rapidly develop next-generation prototypes and serve high-quality, high-volume manufacturing
  • Metamorphic manufacturing - on-demand shaping of high-quality structural components
  • Impulse joining - suite of methods that allows for high strength metallic weldments without melting
  • Development paths and commercial opportunities

Dr. Glenn Daehn, Fontana Professor, Department of Materials Science and Engineering, Ohio State University

17:30  Questions and Discussion

17:40  Chair's Closing Remarks - Day 1

17:45-18:45 Networking Drinks Reception For All Attendees Sponsored By Rifast

 

Day 2: Wednesday, February 20, 2019

Enabing Greater Integration, Reduced Process Complexity, More Flexible And Increased Production Capacity With Industry 4.0, Simulation And Manufacturing Technology Advancements

08:00  Coffee And Registration

09:00  Morning Chair's Opening Remarks

Elie Tohme, Director, Body Engineering,Karma Automotive

UNDERSTANDING AND REALIZING THE POTENTIAL FOR DIGITALIZATION AND INDUSTRY 4.0 MANUFACTURING

09:10  Industrial Internet Of Things (IIoT) And The Future Of Electric Vehicle Manufacturing - Overcoming Challenges To Achieve Profitability

  • Functional requirements from an architecture perspective for EV manufacturing
  • IIoT design principles and approaches
  • Importance of big data analytics in EV manufacturing
  • Implementation case studies of EV OEMs / models
  • Growth opportunity areas - ecosystem participant approaches to overcome challenges to meet profitability

Vishwas Shankar, Research Manager,  Business Strategy & Innovation Group - Mobility North America, Frost & Sullivan

09:40  Questions and Discussion 

09:50  Redefining New Vehicle Design And Transforming Traditional Production: Development Of The Uniti City EV

  • New approaches to structure design, safety, sustainability and manufacturing scalability
  • How Digital Twin technology is being implemented for each vehicle and each production factory, as well as planned tracking of in-service data to improve future designs and also production facilities
  • Adoption of digital manufacturing approaches and virtual prototyping of a serial production line including cost modelling and logistics
  • Development of partnerships and collaboration in manufacturing of the vehicle's lightweight carbon fiber reinforced thermoplastic composite chassis for lower cycle times and recyclability, as well as the potential for hybrid materials through additive manufacturing processes 

Lewis Horne, CEO and CTO, Uniti

10:25  Questions and Discussion 

PANEL -  SENIOR ARCHITECTURE AND BODY ENGINEERS

10:35  Evolution Of Platforms And Architectures For EV And Their Implications For Body Design, Structures, Materials And Manufacturing Processes

Elie Tohme, Director, Body Engineering, Karma Automotive

Lewis Horne, CEO and CTO, Uniti

Panel Chair: Vishwas Shankar, Research Manager,  Business Strategy & Innovation Group - Mobility North America, Frost & Sullivan

11:15  Networking Coffee Break In Exhibition Area

BODY STRUCTURES AND EV ASSEMBLY

11:45  Body Structure Evolution From ICE (Internal Combustion Engine) To ACES (Automated, Connected, Electric And Shared) Vehicles

  • Evolution of body structure design - transitioning from ICE to EV vehicles
  • Mass saving premiums ($ per kg mass saved) for the various lightweighting options for automotive body structures
  • Lightweighting and design advantages offered by advanced high strength 3rd Gen steels applied to EV structures
  • Lightweight body structure designs using 3rd Gen steels taking full advantage of well-established conventional body shop practices with manufacturing and assembly methods suitable for high volume production

Harry Singh, Senior Product Application Engineer, United States Steel Corp.

12:05  Questions and Discussion

DIGITAL TWIN

12:10  Adopting Digital Twin For Integrated Design And Manufacturing To           Reduce Process Time

  • Enabling a digital footprint of a product from design to development and throughout the entire product life cycle
  • Modelling and simulating real time manufacturing processes
  • Managing the performance, effectiveness, and quality of fixed assets such as machines, lines, and plants using advanced visualization, IoT, and analytical tools
  • Case studies on digital twin in automotive design and production

Nathan (Nate) Hartman Ed.D., Dauch Family Professor of Advanced Manufacturing and Dept. Head Director, Digital Enterprise Center, Co-Director, Indiana Manufacturing Competitiveness Center, Purdue University

12:40  Questions and Discussion   

12:50  Networking Lunch In Exhibition Area

13:50  Afternoon Chair's Opening Remarks

Vishwas Shankar, Research Manager,  Business Strategy & Innovation Group - Mobility North America, Frost & Sullivan

DEVELOPMENTS IN ADVANCED MANUFACTURING PROCESSES AND MATERIALS CUSTOMIZATION

NEURAL NETWORKS IN JOINING

13:55  Lightweight Fastening And Joining Update

  • Fastening design enhancements Flow Drill (FDS)
  • Application of neural networks to joining processes
  • Future areas of investigation

Dr. Brandt Ruszkiewicz, Ph.D, Lead Development Engineer, Semblex Corp.

EXPLOSION CLADDING PROCESS

14:15  Dissimilar Metal Welding Best Practices

  • The explosion cladding solid state welding process for high shear strength and tensile strength joins
  • Cladding steel with corrosion resistant alloy metals
  • Joining compatible and non-compatible metals

Warren Salt, Director of Business Development, NobelClad

14:35  Questions and Discussion

INCREMENTAL FORMING

14:45  Maximizing Lightweighting In Steel Automotive Bodies And Frames With    The Steel Tube Air Forming (STAF) Process

  • Hotel metal air forming
  • Flange forming technology
  • Optimization of hot forming process

Ryuichi Funada, Technical Marketing, STAF Project, Sumitomo Heavy Industries

15:10  Questions and Discussion

15:15  Networking Coffee Break In Exhibition Area

MANUFACTURING PROCESS INNOVATION

15:45  Composite Materials Simulation And Modeling For Enhanced Lightweight Body Structures

  • Lightweighting opportunities for composites in an automobile
  • Predictive modeling for manufacturing of composites
  • Virtual design of composites
  • New developments in composites - leverage for next generation automobiles

Dr. William Rodgers, Technical Fellow, Chemical and Materials Systems Laboratory, Research and Development Center, General Motors

16:10  Questions and Discussion

MATERIALS JOINING LOOKING AHEAD

16:15  Challenges On Dissimilar Materials Joining - Role Of The Manufacturing And Materials Joining Innovation Centre (Ma²JIC)

  • Looking ahead at the development of new materials and innovative joining solutions
  • Cost-efficiency, driving weight savings, performing for the required application, and addressing the components and material life cycle
  • Impactful technologies and plans to address US manufacturing challenges

Dr. Antonio Ramirez, Ma²JIC Director, Professor, Welding Engineering Program, Materials Science and Engineering, The Ohio State University (OSU)

16:40  Questions and Discussion

ADDITIVE AT LARGE SCALE

16:45  Progress Update On Manufacturing Process Enhancement Through Additive At Large Scale With Metals

  • Scaling up additive and 3D manufacturing for metals
  • Current capabilities - Where can additive manufacturing support high volume applications now? - In future?
  • Where is the break over volume in industrial additive manufacturing? - How fast can you do it and at what volume are you better off just making the tool?
  • Case studies on potentially transformational applications

Dr. Andrzej Nycz, R&D Staff, Manufacturing Demonstration Facility (MDF), Wire-Arc Metal Additive Manufacturing Technical Lead, Oak Ridge National Laboratory (ORNL)

17:10  Questions and Discussion 

17:15  Chair's Closing Remarks - Apple TV and Champagne Draw

17:20  End of Conference

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LEARNING BENEFITS

Continuing Its Annual Output Of Technical Discussions And Networking Opportunities

This Summit Brings Together The Latest OEM Case Studies Looking At The Joining, Forming And Manufacturing Of Lightweight Materials

This exciting two-day agenda will feature the latest case studies on the practical application of the latest manufacturing technologies for joining, forming and quality assurance applicable to a wide spectrum of materials. Looking at the most suitable manufacturing processes for diverse strength aluminum, steel, magnesium and composites, no similar event will provide the same depth of knowledge and level of details to aid the cost effective and process efficient adoption of new technologies.

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