The 3rd Annual Lightweight Vehicle Manufacturing Summit 2016

3RD LIGHTWEIGHT VEHICLE MANUFACTURING 2016JOINING, FORMING & QUALITY ASSURANCE SUMMIT

www.global-lightweight-vehicle-manufacturing.com

Register By FridayOctober 30, 2014

• Upset Protusion Welding

• Friction Stir Welding

• Magnetic Pulse Technology

• Resistance Spot Welding For Aluminum

• Robotic Friction Stir Welding

• Structural Bonding For Aluminum And Steel

• Manufacturing Quality Control

• Corrosion Mitigation

The Most Practical Automotive Summit Bringing Insights Into The Latest Breakthroughs In High Volume Cost Effective Vehicle Manufacturing

MITIGATE CORROSION FOR MIXED MATERIALS: Clarifying Which Corrosion Mitigation Techniques Are Being Effectively Used By OEMs To Maximize Joints Durability

ACHIEVE EFFECTIVE 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

KEEP JOINING COSTS TO MINIMUM: Comparing The Cost Vs. Resistivity Performance For Laser Welding, Resistance Spot Welding And Structure Bonding For Dissimilar Materials Such As Diverse-Strength Steel, And Carbon Fiber Composites

SHORTEN PRODUCTION CYCLES: Learn How OEMs Are Implementing The Very Latest Joining And Forming Methods To Drastically Reduce Production Cycles

MANAGE COMPOSITE PAINTABILITY: Optimizing Composites Properties Through The Processing And Forming To Maximize Parts Paintability

EVALUATING REPAIRABILITY STRATEGIES: Assessing Joint And Material Reparability To Better Understand Vehicle Parts Lifecycle And Repair Costs

24 - 25 February, 2016 | Detroit, Michigan

Organized By:

CO-SPONSORS:

SAVE UP TO 20% WITH GROUP DISCOUNTSCALL FOR RATES: (1) 800 721 3915

Mark Voss Engineering Group Manager Body Advanced Technical Works General Motors

Stephen Logan Sr. Technical Specialist -Lightweight Metals and Manufacturing Projects - Advanced Development Engineering FCA US LLC

Khaled W Shahwan Fellow AIAA, Innovation & Advanced Development Engineering (ADE) Fiat Chrysler Automobiles

Dr. Surender Maddela Sr. Researcher, Lightweight Material Processing GM R&D

Francois Nadeau Technical Leader Aluminum Assembling TechnologiesNational Research Council Canada

Joy Forsmark Technical Expert Light Cast MetalsFord Motor Company

Danick Gallant Research Agent Aluminum Technology Centre (NRC)

The Latest OEM Case Studies On:

Implementing Advanced Lightweight Materials Joining Techniques,Corrosion Mitigation And Quality Assurance To

Enable Maximum Resistivity And Performance For Lightweight Multi-Material JointsIncluding Diverse-Strength Aluminum, Steel, Magnesium And Composites At Lower Costs And Shorter Production Cycles

Insights From OEM Manufcturing Experts

2016 HEADLINE SPONSOR

NETWORKING BREAK SPONSORS:

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

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 excellentTechnical Fellow

General Motors

Manufacturing High Performance Parts Quicker, At A Lower CostSuccessfully securing its place as one of the most sought after manufacturing conferences within the automotive industry the GALM Series Lightweight Vehicle Manufacturing 2016 Summit is returning back in its 3rd year with a brand new agenda that will focus on resistivity and quality assurance.

The program has been completely revamped to address the most pressing issues relevant to the OEMs today.

To address the raising concerns for OEMs with the ultimate goal of lowering costs and shortening production cycles, the 2016 program will look at brand new topics including advanced corrosion mitigation for mixed materials, ways to keep joining costs to minimum, managing composites paintability and evaluating reparability strategies alongside the all important ones of optimizing mixed material joining performance and enhancing formability of the new materials cost effectively.

Enabling Maximum Joint Resistivity And PerformanceWith the increasing pressure on the automotive OEMs to reduce emissions via wider adoption of lightweight materials, the GALM Manufacturing is returning to Detroit in February 24-25, 2016 to address the issues that continue to plague the automotive industry.

Specifically designed for manufacturing experts, the GALM Series Lightweight Vehicle Manufacturing 2016 Summit continues to lead the industry providing innovative solutions to challenges faced across every OEM. Regardless of which material companies are moving towards the challenges remain the same – how to produce lightweight vehicles cost effectively on the shortest production cycle.

SAVE UP TO 20% WITH GROUP DISCOUNTSCALL FOR RATES: (1) 800 721 3915

Comprehensive Joining AnalysisDetailed case studies of aluminium-aluminium welding, aluminium-steel welding, steel-steel welding and even an evaluation of magnesium-aluminium bonding to measure it’s viability for a mass production environment

Quality Assurance at all StagesSessions explore all major aspects of the manufacturing process, but with a constant focus on quality. From assessing the life expectancy and durability of joining strengths, to the manufacturing standards to ensure material integrity and even the comparison of results for varying corrosion mitigation techniques, quality is examined on a forensic scale.

Mass Production of Composites A comprehensive analysis of different forming techniques for composites in advanced shapes, in order to show if an OEM can mass produce them on a scale where the high level of volume is matched only by the high level of quality.

Paint & Finish Meticulous evaluation of industry wide paint issues, including ensuring maximum weld paintability in metals, and measuring thermal expansion properties to negate potential paintability complications.

Reasons To Attend

A culmination of thought leaders from OEMs, suppliers

and innovatorsChief Operating Officer

Local Motors

Venue Information

Detroit Marriott at the Renaissance Center400 Renaissance DriveDetroit, MichiganUSA

DAY 1: ADVANCED JOINING TECHNIQUES FOR DISSIMILAR METALS SUCH AS DIFFERENT STRENGTHS OF ALUMINUM AND STEEL, INCLUDING LASER WELDING, ROBOTIC FRICTION STIR WELDING AND MAGNETIC PULSE TECHNOLOGY

Day 1Wednesday February 24, 2016

8.30 Chair’s Opening Remarks

Joining Methods For Diverse-Strength MetalsAssessing Laser Welding And Resistance Spot Welding For Aluminum And Steel Parts With Varied Strengths To Identify Which Joining Technology Is Helping OEMs Achieve Better

Quality Results At Lower Costs

UPSET PROTRUSION JOINING

8.45 Evaluating The Upset Protrusion Joining (UPJ) Method To Join Magnesium Castings To Dissimilar Metals

•Discussingthechallengesofjoiningmagnesiumcastingstodissimilarmetals

•Establishingbenchmarkjointperformanceresultsformagnesiumdie-castingstoaluminumsheetmaterialusingtheSPRprocess

•IntroducingtheUPJprocessforjoiningmagnesiumcastingstodissimilarmetalstoimprovethecycletime

•DiscussingUPJjointperformanceresultsandcomparingtobenchmarkSPRjointperformance

Stephen Logan, Sr. Technical Specialist -Lightweight Metals and Manufacturing Projects - Advanced Development Engineering, FCA9.15 Question & Answer Session

FRICTION STIR WELDING

9.25 Investigating Friction Stir Welding Of Aluminum To Steel For Armored Vehicles

Martin McDonnell, Mechanical/Weld Engineer, U.S. Army Tank, Automotive, Research, Development, And Engineering Center (TARDEC)9.55 Question & Answer Session

MAGNETIC PULSE TECHNOLOGY

10.05 Leveraging Magnetic Pulse Technology For Advanced Manufacturing Processes in Automotive

•UnderstandingMagneticPulseTechnologyandwhatishastooffer

•ExaminingtheapplicationofMagneticPulseTechnologyforjoiningofdissimilarmaterialandforformingapplication

•Understandinghowthetechnologycanbeappliedtocar-bodyrelatedjoiningandpartsformingtasks

Jean-Charles Boutin, Business Development Director, Bmax10.15 Question & Answer Session

10.20 Morning Refreshments In Exhibition Showcase Area Sponsored By BmaxRESISTANCE SPOT WELDING FOR ALUMINUM

10.50 Joining Simulation: Using Innovative Simulation Software To Achieve Higher Accuracy For Resistance Spot Welding Aluminum In Terms Of Its Brittleness

•Comparingthecostofresistancespotweldingforaluminumvs.self-piercedrivetstodeterminedifferencesincapitalcostsforeachmethod

•Assessingstrategiesforincreasingtheresistivityof700-500aluminumwithinresistancespotweldingtomaximizeperformancewhilstminimizingcosts

•HearinghowanOEMismonitoringspotweldswithprocesscontrolsystemssuchasresistancecheckersandDCtransformers

11.20 Question & Answer Session

MULTI MATERIAL JOINING

11.30 Evaluating Different Joining Techniques To Understand Which Can Deliver The Most Cost And Time Effective Solution For Mixed Material Joining For Lightweight Vehicles

•Evaluatingtheoptimaljoiningtechniquesforwhenyouhavesteel,aluminumandcarbonfiberinthesamecar

•Determiningwhatcanbedoneatthelevelofjoiningtopreventcorrosionwhendissimilarmaterialscomeintocontact

•Determiningwhichjoiningtechniquesoffertheoptimaltime-andcost-efficienciesformixedmaterialapplications

•Overcomingthekeychallengesofoptimizingmixedmaterialjoiningtechniquesatmassproducedscales

Craig Cowan, President, RB&W


ROBOTIC FRICTION STIR WELDING

11.50 Showcasing Robotic Friction Sir Welding Developments For The Automotive Industry

•PresentingFSWapplicationwithaparticularfocusinthecontrolcapabilitiesoftheroboticsystemandspecificrequirementsdrivenbytheapplication

•Understandinganovelapproachforafrictionstirspotandstitchdevice,presentedasaleverageofthelinearroboticsystem

•HighlightingthebenefitsofusinganexternalheatsourcecombinedwithfrictionstirweldingtominimizeforcesinaluminumextrusionsandincreasejointresistanceinAl/Steeljoining

•Benchmarkingautomotiveandrailcarindustryapplicationsfocusingonextrusion’stolerancesaswellasself-clipsedextrusions

François Nadeau, Technical Leader Aluminum Assembling Technologies, National Research Council Canada12.20 Question & Answer Session

12.30 Lunch In Exhibition Showcase Area

Joining Methods For Mixed Materials And Composites, UHSS Stamping And Meeting Material Supplies

Evaluating Innovative Joining Methods For Mixed Materials & Composites, Minimizing Costs & Weight Of UHSS Parts

Utilizing Advanced Stamping Method & Scrutinizing Aluminum Supply Chain Potential

Session Chair: Dr. Surender Maddela, Sr. Researcher, Lightweight Material Processing, GM R&DSTRUCTURAL BONDING FOR ALUMINUM AND STEEL

1.30 How An OEM Has Used Bonding For Structural Aluminum-Steel Parts: Measuring Performance Against Process Cycle Times And Effectiveness

•Examiningheatingandcoolingcyclesforaluminum-steelstructuralpartsbondingtogaugepartsresistivity

•Comparingcostsvs.resultsformechanicalandchemicalbondingforaluminum-steelparts

•Assessingtheresponseofstructuralbondingforaluminum-steelpartstocoatingtoensuremaximumquality

•Learningfromexperiencesonstructuralbondingintheaerospaceindustrytounderstandhowtoimplementaluminum-steelstructuralbondinginamassproductionenvironment

•Understandingtheimpactofhightemperaturesonmaterialsinbondingforaluminum-steelstructuralpartstominimizeimperfections

Session Chair: Dr. Surender Maddela, Sr. Researcher, Lightweight Material Processing, GM R&D2.00 Question & Answer Session

JOINING TECHNOLOGIES WITH AND WITHOUT FASTENERS

2.10 Using Various Joining Technologies Other Than Welding For Aluminum And Mixed Materials To Evaluate Their Performance

•Explaininghoweachjoiningprocessworkstounderstandtheirapplicationpotentialbasedonmaterialtypeandthickness

•Discussjoiningdissimilarmaterialswithadhesiveincombinationswiththesejoiningtechnologiestoevaluatetheireffectiveness

•Showingcurrentapplicationsanddiscussingtheadvantagesandlimitationofeachprocess:Clinching,ClinchRivet,PunchRivet,VarioPointClinchingandSpecialInsertionFasteners

Troy Waldherr, Sales Manager, TOX Pressotechnik-North America2.25 Question & Answer Session

MIXED MATERIAL BONDING

2.30 Presenting Practical Considerations Of Mixed

Material Bonding To Support Lightweight Vehicle

Design & Manufacturing

•Reviewofthepracticalconsiderationsrequiredintheadhesivejoiningofmixedmaterial,usedinsupportofthevehiclestructurallightweightinginitiatives

•Examinationofthedesignandprocessrelateddifficultiesintheintegrationofconventionalstructuraladhesivestowardmixedmaterialbondingrequirements

•Introductionofanewgenerationofstructuraladhesivesdevelopedtoaddressemergingtrendsandrequirements,withexamplesofcurrentapplications

Philip E. Weber, Vice President, Product Engineering & Technical Services, Industry and Automotive, Sika Corporation


BONDING: COMPOSITES AND ALUMINUM

2.50 Identifying Key Challenges In Bonding For Carbon

Fiber And Other Composites With Aluminum And Steel

Frames To Understand How To Significantly Optimize

Performance

•Evaluatingearlyexperiencesoncomposite-aluminumbondingtounderstandwhatarethekeychallenges

•Understandinghowtransferablelessonsoncarbonfiber-aluminumjoiningcanbeimplementedinsmall-scalemanufacturing

•Assessinginnovativebondingmethodsforcarbonfiber-aluminumtoidentifyhowtomaximizejoiningstrengthanddurability

•Lookingatdifferentassemblystrategiesandtechniquesthatcouldbeadoptedforcompositesbondingtoallowtheassemblyoutputtoreachmediumvolumeofoutputatminimumcosts


SELF PIERCING RIVETS (SPR)

3.30 Exploring Henrob Self-Pierce Riveting (HSPR) To

Understand Its Application On Aluminum Intensive And

Mixed Material Programs

•ExplainingwhatSPRistounderstandhowitcanbealliedinlightweightautomotiveproduction

•LearningaboutcurrentstatusofmaterialsbeingjoinedwithHSPRinBIW/CIWapplicationsandthetrendinthenearfuture

•Clarifyingwhatiscriticaltotheapplication,andoptimizationofSPRwhenconsideringanaluminumintensiveormixedmetalprogram

Dave Baker, Business Development Manager - NA Automotive, Henrob Corporation

3.40 Question & Answers

3.45 Afternoon Refreshments In Exhibition Showcase Area Sponsored by Henrob Corporation

GENERATION 3 STEEL

4.15 Giving An Overview of The United States Steel

Automotive Solutions to Light weighting

Bernhard Hoffmann, VP Engineering and Product Development, Automotive Solutions, US Steel


4.35 Chair’s Closing Remarks

4.45 - 5.45 Networking Drinks Reception In Exhibition Showcase Area


Day Chair: Dr. Khaled W. Shahwan, Fellow AIAA, Innovation & Advanced Development Engineering (ADE), Chrysler Technology Center, FCA9.00 Chair’s Opening Remarks

ENSURING MAXIMUM JOINING QUALITYOutlining The Latest Advancements In Process Control For

Aluminum-Steel Joints, Life-Cycle Evaluation For Welds And Corrosion Mitigation For Aluminum-Steel And Magnesium To Identify Key Strategies For Ensuring Maximum Part Resistivity

And Durability

BREAKFAST BRIEFING: MANUFACTURING QUALITY CONTROL

9.10 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

•IncludingtheroleofXRFtoaccuratelymeasurethethicknessofelectroplating,passivationandconversioncoatings

•AssessingthecompatibilityofXRFtomeasurethechemicalcompositionofHighStrengthSteels,MagnesiumandTitaniumalloys

Mark Lessard, Business Development Manager, ThermoFisher Scientific9.20 Question & Answer Session

CORROSION MITIGATION

9.25 Examining Corrosion Mitigation Strategies For Cast Magnesium and Mixed Metals Joints

•PresentingtheresultsfromtheUSCARprojectonMagnesiumfrontendResearchandDevelopment

•Exploringstrategiesinvolvingconversioncoatingsande-coatinginconjunctionwithdifferentjoiningtechniquesandMg/Al/Steelcombinations

•Investigatingstructuraladhesivesandtheuseofbodyshopsealant

•PresentingtheresultsofOEMcycliccorrosiontestingfordifferentstrategies

Dr. Joy H. Forsmark, Technical Expert, Light Cast Metals, Ford Motor Company9.55 Question & Answer Session

QUALITY ASSURANCE: ALUMINUM-STEEL JOINING

10.10 Implementing Process Control Systems To Achieve Higher Resistivity Levels In Aluminum-Steel Joining Methods

•Evaluatingmethodsforverificationofaluminum-steeljointqualitytoensuremaximumjoininglife-cycles

•Implementingprocesscontrolsystemsforresistancespotweldingsuchasresistancecheckerstomaximizejointsquality

•Monitoringresistancespotandlaserweldingprocessestomeasureproductioncyclesmoreaccurately

•Analyzinghowsheetclampscreateairgapswithindiverse-strengthaluminumsheetstodeterminewhetheralternativeequipmentset-upswouldsolvethis

•HearinghowanOEMismonitoringspotweldswithprocesscontrolsystemssuchasresistancecheckersandDCtransformers

Session Chair: Dr. Khaled W. Shahwan, Fellow AIAA, Innovation & Advanced Development Engineering (ADE), Chrysler Technology Center, FCA10.40 Question & Answer Session

CLINCHED FASTENERS

10.50 Optimizing The Clinched Fastener/Clinched Component Design And Interface Required For Reduced Mass Applications

•Optimizingtheclinchedfastener/clinchedcomponentdesignandinterfacetomeetrequirementsforreducedmassapplications

•Showcasingimprovementsintheexistingproductlinesandpresentingnewproducts(Light-WeightNutandAluminumclinchedfastenerelement)toallowbetterjointperformanceinharderandlessductilematerial

Jim Erhardt, President, Rifast11.00 Question & Answer Session

11.05 Morning Refreshments In Exhibition Showcase Area Sponsored by RifastLIFE-CYCLE EVALUATION: NUMERICAL SUMULATION OF GALVANIC CORROSION

11.35 Understanding Numerical Simulation of Galvanic Corrosion as a Decision Support Tool for the Design of Aluminum to Dissimilar Materials Assemblies

•In-serviceexposureofgalvaniccouples(Al-StainlessSteel,Al-CFRP,Al-HighStrengthSteel),includingcontinuousmonitoringofgalvaniccurrents

•Usingadvancedelectrochemicalcharacterizationofmaterialsformodelling

•Developmingnovellaboratorymethodforinvestigationofrealgalvaniccorrosionrisks(onthebasisoffieldresults)

•Mitigatinggalvaniccorrosionissuesonthebasisofnumericalsimulation:selectionofmaterials,geometry&fasteners

Danick Gallant, Research Agent, Aluminum Technology Centre (NRC)12.05 Question & Answer Session

PANEL DISCUSSION: REPAIRABILITY

12.15 Assessing Joints And Material Reparability To Better Understand Vehicle Parts Lifecycle And Map Out Repair Costs & Devise Repair Strategies

•Identifyingwhichrepairsarepossibletodeterminewhetherpartscanbesectionedrelativetojoining,weldingorbondingtypes

•Understandingmainguidelinesforrepairtominimizeprocesslifecyclesandcosts

•Streamliningmethodsforidentifyingdamagelevelsonlightweightmaterials

•Howcandifferentstrength-levelsofaluminumberepairedeffectively?

Panel Chair: Dr. Khaled W. Shahwan, Fellow AIAA, Innovation & Advanced Development Engineering (ADE), Chrysler Technology Center, FCA

12.45 Networking Lunch in the Exhibition Showcase Area

High Volume Composite FormingForming And Processing Technologies That Are Being Implemented For Carbon Fiber And Other Advanced

Composites To Determine Which Of These Can Be Adopted In Mass Production Environments

ADVANCED COMPOSITES FORMING

1.45 Evaluating Different Forming Methods For Carbon Fiber, Glass Fiber And Other Composites For Advanced Shapes To Determine Whether It Is Economically Viable To Apply Them In Mass Production

•HowanOEMisperformingadvancedforminganalysisforcompositestoensurehighqualitypartsthatwillbecompatiblewithhighproductionratesfacilities

•Comparinginjectionmoldingvs.hydroformingvs.compressionmoldingforcarbonfiberfromacostvs.benefitstandpointtodeterminewhichformingmethodcanensureshorterproductioncyclesatlowercosts

•Assessingtheimpactofprocessingtemperatureoncompositesformingtoensuremaximumqualityforcompositesforming

•Understandingtheroleofthesupplierinspeedinguptheproductionofcarbonfibercompositestosecurepartsavailabilityformassproduction

•Examiningperformance,paintability,mechanicalpropertiesandappearanceofadvancedcompositesandtheirabilitytobebondedandfastened

•Evaluatinginnovativemethodstoinject,secureandsetresinsforcompositestoachieveshorterproductioncycletimes


FLOW DRILL FASTENING

2.25 Giving An Overview Of The Specificities Related To The Use Of The Flow Drill Screws In Lightweight Assembly To Optimize Production Process

Gene Simpson, Vice President of Quality & Engineering, Semblex Corporation2.35 Question & Answer Session

2.40 Afternoon Refreshments In The Exhibition Showcase Area Sponsored By Semblex Corporation

Enhancing Composite Processing And Maximizing Part Paintability

Understanding How To Enhancing Composite Processing And Maximize Part Paintability

COMPOSITE PROCESSING

3.10 Standardizing Formats For Raw Material Processing To Mitigate Temperature Effects On Composite Materials In Terms Of Appearance Imperfections And Bonding Performance

•Establishingmanufacturingstandardsforcompositeprocessingtoensuremaximummaterialqualityandreducecosts

•Evaluatingmethodstoprocessadvancedcompositessuchascarbonfiberwhilemaintainingjointstrengthandpartperformancerequirements

•Assessingtheheatingandcoolingcyclesforrawcompositematerialsintermsofthesystemsthematerialsarestoredinandhowtheyarepumpedthroughfromthecontainertothejobs

•Testingresin,pigment,norylburyloxetateandacetonelevelsonrawmaterialsaheadoftimetooptimizecompositeprocessing


COMPOSITES PAINTABILITY

3.50 Managing Composite Properties Through Processing And Forming To Maximize Part Paintability

•Measuringthermalexpansionpropertiesofthedifferentcompositematerialstopreventpaintabilityissuesforcompositeparts

•Optimizingthefluidnessandcleanlinessofcompositepanelsurfacestoensureoptimumpaintabilityandultimatelyreducecost

•UnderstandinghowsuppliersandOEMsareusingelectro-staticprimerstoachievemaximumcolorcodingaccuracyandensurecolorcoherence


4.30 Chair’s Closing Remarks And End Of Conference

Day 2Thursday February 25, 2016

DAY 2: CORROSION CONTROL, QUALITY ASSURANCE, COMPOSITE FORMING MAGNESIUM, CASTING AND PAINTABILITY


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

speaking about these issuesAdvanced Material Research

Honda R&D Americas

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