Next-Gen Multi-Material Congress Explores Lightweighting Advances

THREE DAYS ON HOW TO COST-EFFECTIVELY JOIN, FORM
AND DESIGN COMPOSITES AND LIGHTWEIGHT METALS INTO
MULTI-MATERIAL VEHICLE ARCHITECTURES
OEM CASE STUDIES TO COVER:
18-20 August 2015 | Detroit | MICHIGAN
Brand New OEM Case Studies Delivered By:
David Wagner
Technical Leader Lightweight Vehicle Design
Ford
Surender Maddela
Sr. Research & Development Engineer,
Materials Engineering
Nissan Motor Corporation
Stephen Logan
Senior Engineering Specialist
Chrysler
Mark Voss
Engineering Group Manager, Body Advanced
Technical Works
General Motors
www.global-automotive-lightweight-materials-detroit-2015.com
Gregory E. Peterson
Senior Technical Specialist
Lotus Engineering
Nir Khan
Director Of Design
Plasan
Glenn Daehn
Mars G. Fontana Professor Of Metallurgical
Engineering, Executive Director
Honda OSU Partnership Program
Part of In association with
Organised by
2015 PARTNERS CO-SPONSOR NETWORKING BREAK SPONSORS
FEATURED MEDIA PARTNERS
GROUP DISCOUNTS AVAILABLE
SAVE UP TO 20%
See Website For Details
NEXT GENERATION MULTI- MATERIAL JOINING, FORMING AND DESIGN CONGRESS FOR LIGHTWEIGHT VEHICLES
Scrutinizing joining, forming & design
to evaluate the financial feasibility
of introducing composites into high
volume vehicles
Design architecture case studies to
optimize material selection for each
component and introduce them into
the production process
Uncovering the latest advances with
mixed material joining techniques
to examine their suitability for each
application type
Exploring corrosion mitigation
techniques for composite and mixed
material joints to extend the life of the
vehicle and minimize repair costs
ADVANCES IN COMPOSITES
DESIGN PHILOSOPHY
RECYCLING
MIXED MATERIALS JOINING
CORROSION MITIGATION
LIGHTWEIGHTING BEYOND BIW
Managing scrap from lightweight
materials effectively to minimize
material costs
Probing lightweighting solutions beyond
body in white to explore other options for
considerable weight savings

WELCOME TO THE 11th
GLOBAL AUTOMOTIVE
LIGHTWEIGHT MATERIALS CONGRESS
THIS YEAR PROVIDING UNPRECEDENTED DETAIL ON COMPOSITES, JOINING,
MULTI-MATERIAL DESIGN AND RECYCLING INNOVATION.
Minimizing the costs of adopting the latest materials and manufacturing advances to
reduce vehicle weight is the key priority for every large scale OEM in the US.
To deliver the next generation of lightweight vehicles OEMs are critically racing
to reduce the costs and cycle times of carbon-fiber composites, aluminium and
magnesium. From design modeling and corrosion mitigation to recycling, technology is
advancing at break-neck speed and each year OEMs must stay ahead of the learning
curve to remain competitive on the forecourt.
In addition, the last 12 months has seen increasing pressure to further invest in
lightweight solutions to adhere to EPA and NHTSA greenhouse gas emission standards.
THE LARGEST AND MOST TRUSTED LIGHTWEIGHT MATERIALS CONGRESS IS
RETURNING TO DETROIT FOR THE 4TH TIME.
Bursting at the seams with OEM case studies, the expanded 3-day agenda for 2015
will provide more depth across composite joining, forming and design as well as
corrosion mitigation for multi-material joining, aluminium and magnesium forming,
material selection processes, design modelling and recycling. In addition new sessions
will review opportunities to reduce weight through interior, seating and closure design.
Each presentation will focus on ultimately driving down costs and production times to
ease the adoption of lightweight materials into mass-produced vehicle architectures.
WHAT’S SPECIAL ABOUT
GLOBAL AUTOMOTIVE
LIGHTWEIGHT MATERIALS
DETROIT 2015:
SAVE UP TO 20%
www.global-automotive-lightweight-materials-detroit-2015.com + (1) 800 721 3915 info@american-business-conferences.com
Global Automotive Lightweight Materials 2015
will be held at:
Diamond Center
46100 Grand River Avenue Novi
Michigan 48374
Web: www.diamondbanquetcenter.com
Venue Information:
Evaluating new processes, technologies and
advanced materials that have been applied by
OEMs and their partners to scrutinize what can
be adopted in high volumes at optimal costs and
revolutionize vehicle lightweighting
Scrutinizing joining, forming & design to evaluate
the financial feasibility of introducing composites
into high volume vehicles
Exploring the BIWs from the top leaders in the industry
to practically evaluate the latest light weighting
practices they have adopted in their vehicles
With the automotive focus on cost competitiveness
being ever more prominent, uncovering areas
that could add substantial reductions in material
sourcing, design, manufacturing and recycling costs
become an exceptionally appealing angle that will
be thoroughly scrutinized during GALM US 2015
FUTURE FOCUS
ADVANCES IN COMPOSITES EXPANDED
LIGHTWEIGHTING BEYOND BIW EXPLORED
EXCLUSIVE DISPLAY OF BIW
COST REDUCTION DRIVEN
Probing lightweighting opportunities beyond body-
in-white such as interior, seating and closures
Leveraging Forming And Joining Innovation To Drive Down Costs And Time Of Producing Parts
And Utilizing Design Modeling To Enable Mass Adoption Of Composites In Vehicle Architectures
DAY 1: COMPOSITES & CARBON-FIBER FOCUS
Assessing The Latest Multi-Material Joining Techniques And Surface Treatment Solutions To Reduce
Manufacturing Cycle Times And Costs And Mitigate Corrosion Of Lightweight Materials
DAY 2: MULTI-MATERIAL JOINING AND SURFACE TREATMENT FOCUS
Optimizing Material Selection Procedures Across Body, Interior And Closures And Hearing The
Forming And Design Methods For Integrating Lightweight Metals Across The Vehicle
DAY 3: DESIGN AND FORMING FOCUS

INSPECT FOR YOURSELF…
…THE MOST INNOVATIVE BIWs OF 2015
The last 12 months has seen a plethora of lightweight innovation across composites
and aluminium reaching the forecourt. At the 4th Global Automotive Lightweight
Materials Congress 2015 we are delighted to extend our Body-In-White exhibition.
For each of the below vehicles, we will be revealing what lies beneath the aesthetics
and showcasing the core Body-In-White for attendees to inspect and discover.
TESLA MODEL S
This lightweight aluminium body reinforced with high
strength, boron steel elements has been designed with
electric powertrain in mind. Regularly in the spotlight
for innovation, see how Tesla have brought together
optimal material selection and joining methods to
create this world-leading BIW
2014 RANGE ROVER SPORT
The all-aluminium body of the 2014 Range Rover Sport
outsold any other Jaguar or Land Rover model when it hit
the forecourts. 800 pounds lighter, this BIW is a pinnacle of
engineering
FORD F-150
Having stormed its way through the US automotive market,
the F-150 continues to sell as quickly as they are made. The
new aluminium body has shaved 700 pounds off its former
steel ancestor. Following the display of the full vehicle in
2014, the core BIW will now be revealed for 2015
PLUS: LOTUS EVORA FULL VEHICLE
We are also excited to announce the inclusion of a Lotus
Evora in our exhibition showcase. Full details to be
announced shortly
SAVE UP TO 20%
BODY-IN-WHITE EXHIBITION RETURNS

CARBON FIBER AND ADVANCED COMPOSITES
Leveraging Forming And Joining Innovation To Drive Down Costs And Time
Of Producing Parts And Utilizing Design Modeling To Enable Mass Adoption
Of Composites In Vehicle Architectures
Day 1Tuesday 18th
August 2015
9.20 Chair’s Opening Remarks
KEYNOTE: MULTI MATERIAL LIGHTWEIGHT VEHICLE
ARCHITECTURE
9.30 Reducing The Weight Of Ford’s Flagship Five
Passenger Sedan Through Cutting Edge Approach
To Multi Material Vehicle Design And Manufacturing:
Shaving 364kg Off Vehicle Weight
• Giving a project overview and explaining the MMLV design
and material selection principals adopted in the project
• Defining steps adopted by OEM and Supplier partner to
develop manufacturing strategies that enabled the multi
material vehicle assembly
• Learning about methodology used to select material based
on application type
• Sharing results from NVH, durability, safety and corrosion
testing
• Examining life cycle assessment of the MMLV as compared
to the baseline production vehicle in terms of Global
Warming Potential and Total Primary Energy
DavidWagner,TechnicalLeaderLightweightVehicleDesigner,Ford
10.00 Question & Answer Session
COMPOSITES
Applying The Latest Joining, Forming And Design
Innovations To Reduce The Cost And Cycle Time Of
Integrating Composites Into Multi-Material Architectures
COMPOSITES DESIGN & MODELING
10.10 Leveraging Modeling Tools To Predict
Composite Behaviour And Design Parts For Next-
Generation Vehicle Architectures
• Appraising available tools and methods to design composite
parts more effectively to enable reduction of associated
costs and cycle times
• Assessing full potential of design philosophy adjustments to
enable transferability of parts across models
• Examining part specific design advancements to evaluate
the viability of the mass production of composite parts
• Enabling accuracy in computer modeling to predict
composite behaviour when designing a part
VenkatAitharaju,CompositeMaterialModelingExpert,Staff
Researcher,GeneralMotors
COMPOSITE WHEELS
10.50 Learning About The Use Of Composite Wheel
Technology To Provide Significant And Measurable
Weight Savings
• Understanding the specifics of composite wheel systems to
learn about mass saving opportunities
• Learning how weight saving can be enacted while using
composite wheel systems without revising infrastructure
JamesArdern,GeneralManager,Lacks
11.00 Morning Refreshments In Exhibition Showcase Area
Sponsored by Lacks
COMPOSITES FORMING
11.30 Examining Composite Forming Processes And
Advanced Technologies To Leverage Their Use In
Vehicle Weight Reduction Practices
• Learning how to design vehicle architectures for composites,
and inestigating predictive structural analysis
• Choosing and integrating the right composite manufacturing
technologies to allow cost effective mass production, and
efficient weight reduction
• Showing examples of high volume composite components
applied to vehicles, and testing their effectiveness
NirKahn,DirectorofDesign,Plasan
COMPOSITE PARTS DESIGN
12.10 Increasing Composite Usage In Lightweight
Cars By Eliminating “Black Metal” Design
• Defining how parts design impacts producibility of
automotive composite parts
• Understanding how to be more selective in use of expensive
materials to lower cost without lowering performance
• Examining concurrent design of part features and process/
tooling parameters
• Studying the impact of engineering software on part design
to measure producibility trade-offs
EdBernardon,VicePresident,StrategicAutomotiveInitiatives,Siemens
PLMSoftware
CARBON FIBER COMPOSITES: REDUCING COSTS
12.30 Evaluating Opportunities To Optimize Value Of
Automotive Composite Structures
• Describing emerging open access manufacturing R&D
facilities and public private partnerships to commercialize
composite technology and products
• Reviewing cost reduction strategies throughout the value
chain from carbon fiber precursors to components and
assemblies
• Describing opportunities for reduce cost of carbon fiber and
associated market impacts
• Describing emerging and potential transformational
materials and processes for composites to improve value
• Describing the challenges of rapid growth in the carbon fiber
industry to accommodate potential demand
RaymondBoeman,ProgramDirector,EnergyPartnerships,OakRidge
NationalLaboratory
1.10 Networking Lunch In Exhibition Showcase Area
Sponsored by Bolhoff
FIBER-REINFORCED POLYMERS
2.10 Demystifying Automotive Composites To
Evaluate Full Potential For Significant Mass Saving
• Examining Fiber Reinforced Polymer (FRP) composite
materials to understand their offerings in modulus and
specific strength
• Learning about major advantages of FRP that offer broad
range of materials and processes that can be tailored to
meet mass, cost and performance requirements
• Understanding intricate details of the specific processes to
select the right materials and processes for each application
• Summarzing diverse nature of automotive structure
requirements and complexity involved in selection of
the right material and process to provide cost effective
customized solutions
BhaveshShah,SeniorAdvancedTechnologyDesignReleaseEngineer,
GeneralMotors
ALUMINUM APPLICATIONS
2.50 Examining The Increasing Role Of Aluminum
In Automotive Lightweighting To Define Its Stance
Among Other Materials
• Understanding automotive aluminum usage developments
over the past decade and the role of aluminum in the new
automotive industry
• Reviewing the effectiveness of aluminum in automotive
applications with respect to lightweighting, safety and
sustainability
• Examining the role of partnerships between material
suppliers and OMEs to address the five primary concerns
of styling, strength and safety, durability, supply risk and
sustainability
TomBoney,VicePresidentandGeneralManager,AutomotiveValueStream,
Novelis
3.10 Afternoon Refreshments In Exhibition Showcase Area
Sponsored by Novelis
CARBON FIBER SUPPLY CHAIN: PANEL DISCUSSION
3.40 Investigating Availability Of Carbon Fiber And
Building Effective Supply Chains To Reduce Costs For
High Volume Use
• Mapping out suppliers of carbon fiber to devise strategy on
the material sourcing at the competitive price
• Forecasting supply volumes for carbon fiber to evaluate their
future costs and availability
• Investigating ways to manage stakeholders involved in
carbon fiber business to help cost reduction strategy
• Analyzing steps to take internally to manage carbon fiber
component forming costs more effectively
MarkVoss,EngineeringGroupManager,BodyAdvancedTechnicalWorks,
GeneralMotors
RaymondBoeman,ProgramDirector,EnergyPartnerships,OakRidge
NationalLaboratory
CARBON FIBER AND COMPOSITE RECYCLING
4.10 Leveraging Ways To Handle Composite Scrap
More Effectively To Take Full Advantage Of Reducing
Material Costs
• Understanding the recycling properties of the new
composites to evaluate production cost reduction potential
• Examining the creation of processes that allow to utilize
composites in an effective manner
• Evaluating available technologies for separation of
composites more effectively to leverage the existing reuse
potential
• Devising a holistic strategy on scrap management to
considerably reduce scrap output
MULTI MATERIAL JOINING
4.50 Evaluating Different Joining Techniques To
Understand Which Can Deliver The Most Cost And
Time Effective Solution For Mixed Material Joining
For Lightweight Vehicles
• Evaluating the optimal joining techniques for when you have
steel, aluminium and carbon fiber in the same car
• Determining what can be done at the level of joining to
prevent corrosion when dissimilar materials come into
contact
• Determining which joining techniques offer the optimal
time- and cost-efficiencies for mixed material applications
• Overcoming the key challenges of optimizing mixed material
joining techniques at mass produced scaleses
CraigCowan,President,RB&W
5.10 Chair’s Closing Remarks
5.20 - 6.20 End of Day Networking Drinks
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

ChairedByJohnKCatterall,GSSLTLeaderUnderbodyStructure,Global
BodyWarrenTechnicalCenter,GeneralMotors
Breakfast Briefing Sponsored By THERMOFISHER
SCIENTIFIC
MANUFACTURING QUALITY CONTROL
8.30 Utilizing Hand Held XRF (X-Ray Fluorescence)
To Confirm The Chemical Composition Of Aluminum
And Other Alloys to Ensure Quality Control Over The
Materials Throughout Automotive Manufacturing
• Including the role of XRF to accurately measure the
thickness of electro plating, passivation and conversion
coatings
• .Assessing the compatibility of XRF to measure the chemical
composition of High Strength Steels, Magnesium and
Titanium alloys
MarkLessard,BusinessDevelopmentManager,ThermoFisher
Scientific
SURFACE TREATMENT AND COATINGS
8.50 Analyzing Innovations In Surface Treatment
Techniques And Coatings To Minimize Cracks And
Defects In Multi-Materials Applications
• Examining availability of coating technologies that maximise
material protection based on the joint type over long term
under various environmental conditions
• Factoring in the cost indicator related to the long term
performance of the corrosion vs. protection method applied
to examine most suitable solution based on the vehicle class
• Understanding coating selection processes based on the
material type to reduce corrosion when joining composites
with magnesium, aluminium and steel
• Apprehending corrosion mechanism based on the material
and join type to enable selection of the most suitable
treatment method
• Scrutinizing cutting edge surface treatment and coating
solutions claiming to improve resistance to galvanic
corrosion to evaluate performance on difficult joints and
materials highly susceptible to corrosion
SurenderMaddela,Sr.Research&DevelopmentEngineer,Materials
Engineering,NissanMotorCorporation
SURFACE CONDITIONING
9.30 Advanced Materials’ Surface Conditioning
Technology For Automotive Lightweight Materials
• Examining adhesion challenges in processes such as
joining, printing, coating, and painting with increasing use of
lightweight materials
• Reviewing the surface treatment and surface modification
steps which have increased in criticality during automotive
production while using advanced lightweight materials such
as Aluminum, Sheet Moulding Compound (SMC), Carbon
Fiber (CFRP), Magnesium and High Performance Polymers
• Understanding risks associated with using solvent based
wet chemicals for priming and evaluating the benefits with
utilizing atmospheric and low pressure plasma technology
for surface conditioning
AndyFStecher,President/CEO,PlasmatreatNorthAmericaInc.
SENSITIVE ROBOTICS
9.50 Utilizing Sensitive Robotics To Enable Cost-
Efficient Production Of Lightweight Materials
• Examining the need for automated production & processing
in the automotive industry to help comply with strict guide
lines on cost-efficiency, quality and process safety related to
lightweight materials
• Learning about sensitive robotics as a solution to full flexible
automation or/and human-robot-collaboration
• Understanding how problematic areas as grinding,
polishing, burrs, glueing, sensitive handling can be
universally automatedg
Dr.RonaldNaderer,CEO,FerRoboticsCompliantRobotTechnologyGmbH,
Berndorf
10.05 Morning Refreshments In Exhibition Showcase Area
Sponsored by Berndorf
ADHESIVES WITH MINIMAL REQUIRED PRE-
TREATMENT
10.35 Identifying Adhesives Which Require Minimal
Pre-Treatment And Provide High Lateral Joint
Strength
• Evaluating performance of advanced adhesives with
minimal or no required pre-treatment vs. adhesives with
required pre-treatments to examine the resulting number of
joints, joint strength and advancements in cycle times
• Examining the impact of advanced adhesives with minimal
treatment on the cure time to and adjustments in production
schedules
• Inspecting future availability and application of adhesives
with minimal to no pre-treatment to evaluate their impact
on the multi material vehicle productio
UPSET PROTRUSION JOINING
11.15 Evaluating The Upset Protrusion Joining (UPJ)
Method to Join Magnesium Castings to Dissimilar
Metal
• Discussing the challenges of joining magnesium castings to
dissimilar metals
• Establishing benchmark joint performance results for
magnesium die-castings to aluminum sheet material using
the SPR process
• Introducing the UPJ process for joining magnesium castings
to dissimilar metals to improve the cycle time
• Discussing UPJ joint performance results and comparing to
benchmark SPR joint performance
StephenLogan,Sr.TechnicalSpecialist-AdvancedLightweightPrograms,
MaterialsEngineeringGroup,FiatChryslerAutomobiles
FLOW DRILL FASTENING
11.55 Giving An Overview Of The Specificities Related
To The Use Of The Flow Drill Screws In Lightweight
Assembly To Optimize Production Process
GeneSimpson,VicePresidentofQuality&Engineering,Semblex
Corporation
12.05 Networking Lunch Sponsored by Semblex
MIXED MATERIAL BONDING
1.05 Engineering Vehicle Lightweighting With
Advanced Adhesive Technology To Maximize Weight
Saving Potential
PhilWeber,VicePresident,ProductEngineering&TechnicalServices,
IndustryandAutomotive,Sika-US
JOINING TECHNOLOGIES WITH AND WITHOUT
FASTENERS
1.25 Using Various Joining Technologies Other Than
Welding For Aluminum And Mixed Materials To
Evaluate Their Performance
• Explaining how each joining process works to understand
their application potential based on material type and
thickness
• Discussing joining dissimilar materials with adhesive in
combinations with these joining technologies to evaluate
their effectiveness
• Showing current applications and discussing the advantages
and limitation of each process: Clinching, Clinch Rivet,
Punch Rivet, Vario Point Clinching and Special Insertion
Fasteners
TroyWaldherr,SalesManager,TOXPressotechnik-NorthAmerica
PANEL DISCUSSION: CORROSION MITIGATION FOR
COMPOSITE JOINTS
1.45 Benchmarking Corrosion Mitigation Options For
Each Joining Method For Carbon Fiber And Other
Advanced Composites
• Examining methods to increase resistance of advanced
composite joints to galvanic corrosion to select the optimal
performance/cost ration
• Performing corrosion testing under different environmental
and stress conditions to map out performance of joints
based on the type of joining method used
• Learning about the advanced surface treatments and
coatings to maintain the required properties of the joint
• Exploring how to make infrastructure adjustments required
during introduction of coatings and surface treatments to
optimize overall costs related to their use
CLINCHED FASTENERS
2.15 Optimizing The Clinched Fastener/Clinched
Component Design And Interface Required For
Reduced Mass Applications
• Optimizing the clinched fastener/clinched component
design and interface to meet requirements for reduced
mass applications
• Showcasing improvements in the existing product lines and
presenting new products (Light - Weight Nut and Aluminum
clinched fastener element) to allow better joint performance
in harder and less ductile material
ViralVarshney,EngineeringManager,RifastSystemsLLC
2.25 Networking Break Sponsored By Rifast Systems LLC
MODELING MULTI-MATERIAL JOINING
2.55 Integrating Novel Material Joining, Modeling
and Vehicle Design to Optimize Vehicle Mass and
Durability
• Examining proliferation of new joining techniques which
have the potential to change the way vehicles are designed
and manufactured
• Learning about new joining methods as case studies to
understand how to concurrently mature technologies and
vehicle and production system design
• Exploring availability of tools to model materials behaviour
in multi materials structure
• Probing fidelity of different types of modeling software to
predict failures in composites, magnesium, aluminium and
steel when joined together
• Learning about the next steps in using the advanced multi
material modeling to reduce vehicle costs and optimize
overall manufacturing process
Dr.GlennS.Daehn,MarsG.FontanaProfessorOfMetallurgical
Engineering,ExecutiveDirector,HondaOSUPartnershipProgram
SELF PIERCING RIVETS (SPR)
3.35 Exploring Henrob Self-Pierce Riveting (HSPR) To
Understand Its Application On Aluminum Intensive
And Mixed Material Programs
• Explaining what SPR is to understand how it can be allied in
lightweight automotive production
• Learning about current status of materials being joined with
HSPR in BIW / CIW applications and the trend in the near
future
• Clarifying what is critical to the application, and optimization
of SPR when considering an aluminum intensive or mixed
metal program
MichaelLaPensee,VPApplicationsEngineering,HenrobCorporation
ALUMINUM TECHNOLOGIES
3.45 Glancing Inside Aluminum Technological
Innovation To Understand What Is Happening in Alloy
Development, Pretreatment Solutions and Process
Advancement
• Examining R&D activities that are yielding advancements
in aluminum vehicle applications and enabling aluminum
adoption into high volume vehicle production
• Comparing existing alloy capabilities with future state alloy
functionality to support increased safety and durability
• Revealing industry partnerships that will enhance
pretreatment solutions and adhesive bonding technologies
to enable use of aluminum in high-volume vehicles
• Discussing how and why the rolling process speeds
production timelines
ToddSumme,GlobalTechnologyDirector,Automotive,Novelis
4.00 Closing Remarks: Examining The Increasing Role
Of Aluminum In Automotive Lightweighting
MartinSchön,DirectorCorporateR&DAmerica,SapaTechnology
4.20 - 5.20 Networking Drinks In The Exhibition Showcase
Area Sponsored By Sapa Extrusions North America
Day 2Wednesday 19th
August 2015
MULTI-MATERIAL JOINING, FORMING & MATERIAL PROPERTIES
Assessing The Latest Multi-Material Joining Techniques And Surface
Treatment Solutions To Reduce Manufacturing Cycle Times And Costs And
Mitigate Corrosion Of Lightweight Materials

Breakfast Briefing Sponsored By CONSTELLIUM-UACJ
JOINT VENTURE
DESIGNING WITH ALUMINUM
8.30 Evaluating Implementation Of Aluminum In High Volume Car
Body Design And Manufacturing
• Examining properties of aluminum and their influence in
automotive design and manufacturing
• Introducing design with aluminum in mind and aspects of
aluminum in the car manufacturing stream
• Learning about the latest developments of aluminum
products for BIW manufacturing
Dr.AlexGraf,TechnicalDirector,Constellium-UACJJointVenture
DESIGN ARCHITECTURE
Assessing Material Selection Processes For Multi Material
Applications In BIW, Interior And Closures To Leverage
Weight Saving Potential
BODY MATERIAL SELECTION PROCESS
8.50 Reducing Vehicle Weight By Developing A
Comprehensive Design Philosophy
• Creating a design and engineering methodology to support
total vehicle objectives
• Selecting manufacturing approaches that can contribute to
reduced tooling and assembly costs
• Assessing joining technologies: opportunities for reducing
weight and increasing strength
• Creating robust assembly techniques to support non-
traditional construction
GregoryE.Peterson,SeniorTechnicalSpecialist,LotusEngineering
INTEGRATION INTO BODY
9.30 Reviewing Challenges And Identifying
Opportunities With Integration Of Lightweight
Materials Into High Volume Automotive Production -
An OEM Perspective
• Examining the impact of lightweight materials on vehicle
performance beyond weight reductions to assess associated
potential benefits
• Mapping out technical and business challenges with
integration of lightweight materials to devise effective
solution strategies
• Analysing steps to effectively integrate various advanced
lightweight materials into the existing vehicle design and
manufacturing practices
• Inspecting the automotive industry’s role and required steps
in enabling the next generation of advanced materials
RobPeckham,TechnicalIntegrationEngineer,GeneralMotors
HIGH IMPACT VELOCITY FORMING AND WELDING
10.10 Reviewing High Impact Velocity Forming And
Welding For Lightweight Designs
• Reviewing ultra high speed impact forming and welding
• Assessing the potential of ultra high speed impact forming
and welding applications in lightweight designs
• Examining the of these technique on industrial scale to
evaluate their utilization potential
GillesAvrillaud,ChiefTechnologyOfficer,Bmax
10.20 Morning Refreshments Sponsored By Bmax
INTERIOR DESIGN & MATERIAL SELECTION
10.50 Learning Which Materials And CAD Modeling
Techniques Are Being Applied To Reduce The Weight
Of Interior Components
• Examining ways to define the most suitable application
of carbon fiber in the interior parts to evaluate the weight
reduction potential
• Evaluating cost monitoring methods while selecting
materials for different interior applications
• Analyzing available weight saving material options with
inherited structural and crash required performance
features to apply in seating
• Investigating opportunities in lightweighting interior
components to enable considerable cost savings through
their applicability in multiple vehicle types
CLOSURES DESIGN & MATERIAL SELECTION
11.30 Adopting Innovative Design Methodologies And
Choosing Optimal Lightweight Materials To Shave
Maximum Weight From Closures
• Evaluating materials suitability for closure applications
beyond steel and aluminium
• Looking at the design tools for closures to examine their full
potential for weight reduction
• Comparing advanced materials selection and forming
related costs based on the type of material and weight
reductions targets
• Selecting optimal manufacturing technologies to leverage
cost and weight saving implications in closures
MAGNESIUM
Investigating The Role Of Magnesium In Next-Generation
Vehicles Factoring Forming, Joining And Cost Implications
PANEL DISCUSSION: MAGNESIUM COMPONENTS
12.10 Benchmarking Strength, Corrosion Vulnerability
And Forming Speeds To Determine Viability Of Wide
Scale Adoption Of Magnesium Into The Vehicle Body
• Evaluating magnesium supply availability to devise supply
chain strategy allowing to source the material on the
competitive basis
• Examining different applications of magnesium beyond body
panels to examine its full potential in driving down vehicle
weight
• Examining new corrosion mitigation methods to draw
comparison of magnesium part cost and performance vs
other materials
MAGNESIUM FORMING
12.30 Examining How Overmold Precision Molded
Magnesium Is Done To Create Strong, Lightweight
Parts
• Evaluating the specifics of Thixomolding as a casting
method for magnesium to draw comparison with other
methods against the following parameters: Heating
temperature, Cycle time and Component performance
• Appraising material performance with consideration to
uniformity, porosity and cavity during Thixomolding process
to produce magnesium components in comparison to other
processes like die casting
TomDarnell,Co-Founder,LeggeraTechnologies
12.40 Networking Lunch Sponsored by Leggera
Technologies
ALUMINUM ROLE IN AUTOMOTIVE LIGHTWEIGHTING
Reviewing Aluminum Alloys Forming Properties, Material
Availabiluty And Recycling Schemes To Identify Cost-
Saving Options For Aluminum Use In High Volume
Automotive Production
ALUMINUM RECYCLING
1.40 Examining Material Specifications For The
Ford F-150 To Understand The Impact On The
Development Of Effective Recycling Scheme
• Understanding the importance of prompt recycling as a
part of the financial equation of the Ford F-150 program
to evaluate its cost benefit within the overall production
scheme
• Assessing the impact of the production volumes on the
selection of aluminum and stamping suppliers to meet the
recycling specifications
• Exploring the challenges and the solutions with establishing
a practical and cost effective prompt recycling scheme with
the following specifications: 3 aluminum companies, 7 alloys
and 9 alloys specifications
LaurentB.Chappuis,TechnicalExpert-LightweightStampings,Vehicle
ProgramEngineering-SBU,Ford
ALUMINUM ALLOYS
2.20 Probing The Latest Developments In Aluminum
Alloys To Examine Their Performance Within
Automotive Applications
• Learning about alloys for energy absorption to evaluate their
potential in crash management systems
• Understanding pros and cons of 7XXX aluminum alloys
• Learning about high strength 6XXX alloy development to
scrutinize their potential in automotive application
• Examining the difference between ductility and tensile
elongation and measuring ductility in aluminium alloys
DavidLukasak,ChiefMetallurgistNorthAmerica,SapaProfilerAB
ALUMINUM EXTRUSION
2.40 Case Studies: Examining The Very Latest
Advancements In The Use Of Aluminum Extrusion In
Lightweighting
• Reviewing the current automotive landscape with its
‘basic’ use of aluminum and aluminum extrusions in high
volume vehicle production to evaluate the future potential of
designing with extrusions
• Examining the possibility of stretching aluminum extrusion
use into more advanced applications to drive higher
performance and more creative solutions in future vehicle
engineering designs focusing on: Non-traditional alloys (e.g.
5xxx series), Complex bent components and Joining solution
MartinBidwell,PresidentandCEO,MagnodeCorporation
(AluminumExtrudersCouncil)
ALUMINIUM COMPONENTS
3.05 Examining The Capabilities And Limitations Of
Each Forming Technique To Determine The Optimal
Method For Producing Each Aluminium Component
• Learning about extruded aluminum based solutions to
leverage crash management and performance of structural
components
• Evaluating advanced forming techniques to allow integration
of multiple functions into a single profile
• Analyzing how selection of alloy and tailoring of material
gage can help to provide mass and cost benefits whilst
meeting performance targets
SivanathanPrasoody,TechnicalDirectorAluminum-NorthAmerica,
BentelerAluminiumSystems,NorthAmericaInc.
3.35 End Of Day
Day 3Thursday 20h
August 2015
MULTI MATERIAL DESIGN ARCHITECTURE, ALUMINUM FORMING
AND RECYCLING
Optimizing Material Selection Procedures Across Body, Interior And Closures And
Hearing The Forming And Design Methods For Integrating Lightweight Metals
Across The Vehicle
Good mix of talks and speakers and there was more
technical content than I expected. This was a pleasant
surprise. Food, resources and media were excellent.
Technical Fellow - General Motors

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