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Day 1 – 29th November 2022 - Virtual - GMT

Identifying Cost Competitive Solutions for New Joining, Forming, Bonding, and Mechanical Fastening Technologies in High-Volume Production

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09:30 Chair’s Opening Remarks

Setting the context for the conference “The desired production volume, available budget, availability of capital equipment, and needed joint performance are just a few of the variables that must be considered when deciding on the optimal joining solution for a certain application. Today, joining technology selection must be considered within the earliest stages of design taking into account repeatability and easy scale-up for high-volume production”.

MULTI-MATERIAL JOINING MEGATRENDS

09:30 A Megatrend Analysis Of Cutting-Edge Joining Technology Implementation For Mass Production

Focusing on automotive megatrends relating to the latest joining technologies and validation solutions for multi-material combinations. What are the current technology trends in the industry? How can OEM’s collaborate with suppliers to commercialize the latest technology developments for high-volume production? 

              09:45 NEW TECHNOLOGY IMPLEMENTATION CASE STUDY – A FORMULA  FOR SUCCESS    

              Using Simulation Technology For Joining Recycled Plastic

              - Production of recycled plastic

              - Testing of recycled plastic joints

              Okan Otuz CAE & Materials Specialist Mercedes-Benz 

              Ibrahim Halil Kalkan, Research and Development Engineer - Exterior Parts, Mercedes-Benz Mercedes-Benz Türk A.Ş.

              10:15 Questions & Discussion

10:30 – 11:20 Virtual networking 

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OPTIMIZING METALS TO METALS JOINING - PROBLEM-SOLVING & FINDING SOLUTIONS

CASE STUDIES FOCUSING ON KEY SAFETY CRITICAL ZONES & CASH PROTECTION STRUCTURES

Considering Design For Quality & Design For Reliable Manufacturing

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UNIQUE CONCEPTS FOR JOINING DISTINCT ALUMINIUM GRADES WITH STEEL

11:20 Solving Key Problems Associated With Joining Multiple Types of Aluminium to Steel On An Application By Application Basis 

Joining aluminium (Al) alloys and steel can be challenging and not always easy to deliver as a repeatable production process. For example, with some aluminium grades, the presence of a strong oxide layer on the Al alloy surface and the inability to manage the thickness of the Fe-Al intermetallic compound (IMC) has ramifications for achieving sufficient joint strength.  In this talk, the presenter will take a look at some alternative approaches that could potentially be scaled up for mass production.

• Evaluating unique joining concepts for joining multiple types of aluminium with steel
• Examining solutions for specific crash safety and load-bearing applications
• Application of coatings and measures to guard against electrochemical corrosion
• Ensuring anticorrosion performance with welded joints
• Evaluating seal spot welding processes and other concepts as a solution
• Strategies for tooling and scaling up manufacturing when joining aluminium to steel 

Dr Lei Shi, CTO, Nuola Auto Global R&D, Nuola Auto (Shanghai) Technology Co.

Ji Yang Technical Director Nuola Auto

11:40 Questions & Discussion
 

OPTIMISING STAMPING AUTOMOTIVE PANEL COMPONENTS

11:50 Deep Learning Empowered Design for Manufacturability Tools for Stamping Automotive Panel Components

• Deep neural network surrogate models for manufacturability evaluation and optimisation frameworks enabled by the deep-learning-based geometry representations. 
• Case study: design for hot stamping high strength aluminium battery boxes.
• Case study: design for hot stamping ultra-high strength steel B-pillars.
• Case study: design for cold stamping panels with springback issues

Dr Nan Li, Senior Lecturer In Lightweight Design & Manufacturing, Imperial College London

12:40 Questions & Discussion

12:50 Lunch Break

UHSS TO ALUMINIUM 

13:50 Strategies For Making Ultra High Strength Steel & Aluminium Joining Viable In A High Volume Manufacturing Environment

There are several alternate methods for joining high-strength steel and aluminium. You can utilise a friction stir welding method or utilise flow drill screws to act as both a fastener and a drilling instrument when working with extrusions or castings. Flow drill screws necessitate the drilling of intricate pilot holes into the steel, which can be time-consuming and labour-intensive. Self-piercing rivets can be difficult to pierce through UHSS and can also be troublesome in terms of repeatability and scaling to high production volume. So, what are the most recent novel techniques for fusing UHSS with aluminium in a high-volume production setting?

• Comparing innovative welding techniques for joining aluminium to ultra-high-strength steel
• Optimizing surface preparation and pre-treatments
• Taking experimental methods and procedure innovations into a high-volume manufacturing setting
• Implementing state-of-the-art validation and testing
• Results and conclusions

Jose Luis Galaviz, Frames Technical Lead Chassis Group, Stellantis

14:10 Curated questions and discussion 
 

COST EFFECTIVE JOINING SOLUTIONS

14:20 Utilisation Of High Strength Steel And Aluminium For Body Structure And Exploring Cost Effective Joining Solutions

Luiz Zamorano, Body Engineering Manager, Ford Motor Company

14:40 Questions & Discussion

14:50 Afternoon Refreshment Break & Networking
 

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OPTIMAL JOINING OF COMPOSITES TO METALS

ACCORDING TO DESIGN, FUNCTION MATERIAL PROPERTIES & MANUFACTURABILITY

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STEEL TO COMPOSITE JOINING – HIGHLY LOADED STRUCTURES 

JOINING COMPOSITE TO METAL AUTOMOTIVE STRUCTURAL PARTS

15:30 Challenges And Guidelines For Joining Composite To Metal Automotive Structural Parts - Bonding, Fastening And Mixed Techniques

• Composite material parts design for bolting and riveting,
• Fastener type selection
• Bonded joint design
• Surface treatment for adhesion and corrosion prevention

 Andrew Mills, Research Group Leader, Cranfield University

16:20 Questions & Discussion

16:3O Chairs Closing Remarks & Close Of Day 1