0845 Chair’s Opening Remarks

LIGHTWEIGHT REVOLUTION: THE IMPACT OF ADVANCED HIGH-STRENGTH STEEL IN NEXT-GENERATION VEHICLES

09:00 Driving Innovation: The Critical Role Of Advanced High-Strength Steel In Achieving Lightweighting And Safety In The Automotive Industry

Steel's remarkable strength, resilience, and adaptability have made it a key material in the automotive industry for many years. As the sector has developed, manufacturers have had to balance maintaining the highest levels of safety with achieving lightweighting targets for increased fuel economy and lower emissions. The usage of steel in the production of automobiles has undergone a paradigm shift as a result, with an emphasis on advanced high-strength steel (AHSS) and cutting-edge manufacturing processes. This panel discussion will examine steel's critical role in the car industry's pursuit of lightweighting and safety objectives.

09:00 Case Study 1: Integral Development Process On Lightweight Modular Structures & Components To Meet Higher Strength Need

Lei Shi CTO Nuola Auto

09:20 Case Study 2: Overcoming Safety Obstacles And Developing Novel Approaches For Advanced High-Strength Steel In Automobile Structures

09:40 Case Study 3: Driving Towards A Greener Future: The Role Of Advanced High-Strength Steel In Automotive Sustainability 

10:00 Case Study 4: Discussing Industry Strategies: Evaluate The Future Sustainability Of Ultra High Strength Steel In A Circular Economy. 

10:20 Extended Q&A

GREEN INNOVATION IN COMPOSITE

10:40 SOCA – Sustainably Optimised Composite Automotive

• SOCA project presentation, objectives & achievements
• Decarbonising carbon fibre composite (CFRP) for automotive
• High performance recycled carbon fibre
• Available solution for near net-zero CFRP coponent for low-volume automotive application.

Frederic Sicard Technical Specialist composite material & process Jaguar Land Rover

11:05 Questions & Discussion

11:10 Morning Refreshment Break

COMPOSITE MODELING

11:30 Composite Materials Simulation and Modeling for Enhanced Lightweight Body Structures

The presentation will highlight the latest advancements in materials and manufacturing processes designed to make lightweighting with composites more cost-effective for body structures. It will also cover newly developed virtual modeling methods for accurately simulating the characteristics of these advanced materials.

Venkat Aitharaju Senior Researcher, Polymer CompositesGeneral Motors

11:55 Questions & Discussion

JOINING DESIGNS FOR – NEXT GENERATION BEV VEHICLES

12:00 Evaluating CAE Material Cards, Simulation Data And Adhesive Bonding Innovations: Addressing Challenges in Vehicle Manufacturing and Performance Optimization

Discover the upcoming challenges and demand for developing CAE material cards and simulation data in vehicle manufacturing and performance domains. Learn how to apply expand foam adhesive that involves surface treatment and mechanical evaluation.

Okan Otuz CAE/ Materials Specialist Mercedes-Benz Turk A.S.

12:25 Questions & Discussion

END-OF-LIFE STRATEGIES 

12:30 Embedding End-of-Life Strategies to Drive Sustainable Future For Lightweight Automotive

Dervis Eren Unsal Product Sustainability Engineer Ford Otoson

12:55 Questions & Discussion

13:00 Lunch Break

LIGHTWEIGHT SOLUTIONS WITH INTEGRATED BATTERIES 

14:00 Innovative Multi-Material Strategies for Battery Electric Vehicle Architectures: Integrating Battery with Body-In-White for Optimal Lightweighting

In this session, we will delve into the factors impacting multi-material selection for EV battery lightweighting and integration with Body-In-White. We will also explore how OEMs are addressing material requirements while contemplating issues related to the cost, strength, and weight of Battery Electric Vehicles (B.E.V.s).

Simon Xu Engineering Group Manager - Vehicle Optimization, Architecture Strategy General Motors

14:25 Questions & Discussion

INTEGRATION OF MULTILATERAL STRUCTURE

14:30 Unlocking Ultimate Lightweighting: Recent Advances in Dissimilar Material Joining Technologies for Effective Integration of Lightweight Structures

In our pursuit of efficiency, performance, and sustainability, harnessing recent advances in dissimilar material joining technologies becomes paramount. In this talk we will explore how these innovations pave the way for the effective integration of lightweight vehicle structures, reshaping the future of automotive design.

• Exploring the possibilities of weight-optimized joining combinations
• Understand the latest innovations in multi-material joints
• Analyze joining technologies for optimum integration of multilateral BIW structure
• Evaluate future developments on dissimilar material joining for the next-generation BEV’s

Jose luis galaviz Chassis group frames technical lead Stellantis - North America

14:55 Questions & Discussion

15:00 Refreshment Break

JOINING AND BONDING STRATEGIES

15:30 Assessing The Innovative Design Strategy Cost Effective For Joining and Bonding In A Complex Production Assembly Line 

To attain, lightweight we use low-density materials with higher strength-to-weight and higher stiffness-to-weight ratios. This presentation will examine the cost-effective joining strategies for multi-materials vehicle structures.

• How do you select and test the optimal joining technology, at the design stage, what is the overall process and approach?
• Assessing the Methodology for joining technology selection and component analysis to select the welding process
• Analysing cost-effective Joining and Bonding strategies for mass Production Assembly Line
• Evaluate suitable joining candidates for the body in white and supporting architectures specific to B.E.V.’s
• What the future holds for research and development into multi-material joining technologies in a mass production line

15:55 Questions & Discussion

COMPOSITES AND STEEL BONDING

16:00 Advancements in Joining Innovations: Exploring Strategies to Integrate Composites with Steel in Lightweight Vehicles for Enhanced Joint Integrity

• Highlighting applications for adhesive bonding between composites and steel and assessing the pros and cons compared to alternative joining techniques 
• Ascertaining suitable coatings and techniques to reliably join composites to steel to minimise the risk of corrosion and durability issues 
• Addressing the best techniques for attaching fasteners to carbon fiber bodies 
• Understanding specific challenges faced in assembly and how they were solved 
• Reviewing how joining to carbon fiber affects processing time and the relative cost of joint 
• Outlining the advancements in manufacturing technologies needed including the cost of hardware, software, and necessary infrastructure upgrades

16:25 Questions & Discussion

BALANCING PROPERTIES AND PERFORMANCE

16:30 Innovative Methodology To Drive B.E.V. Lightweighting By Evaluating Material Properties Against Key Sustainability Attributes And Performance Benchmarks

• Assess the Framework for material calibration and evaluation
• Examine how material properties can be evaluated based on sustainability characteristics
• Analyse materials suitability for specific structural use based on the performance indicators
• Evaluation process for verification of the results

16:55 Questions & Discussion

LIGHTWEIGHT STRUCTURE 

17:00 Cost-Effective Implementation Of Multi-Material Structural For Lightweighting

• How do you cost-effectively implement interior lightweighting in the multi-material production line?
• Understanding Structural part development, specs, design, tooling
• Learning about Multi-material parts development, specs, design, tooling.
• Minimize development, tooling costs for low-volume projects.
• Reducing costs by enhancing quality.

17:25 Questions & Discussion

NEW MATERIALS AND MANUFACTURING PROCESSES

17:30 Strategic Solutions: Cost-Effective Optimization of Tool Set-Up for Revolutionizing Manufacturing of Multi-Material Body Structures

The introduction of new materials – and processes -  means that new tools need to be cost-effectively integrated into the production process and tool setup. This presentation will investigate the best practices for change management and process re-engineering in the mass production manufacturing line.

• Controlling costs when introducing new materials and manufacturing processes
• Optimizing tool set up to be flexible and adaptable
• Ensuring quality control is maximised during the change management period

17:55 Questions & Discussion

TRANSITION FROM STEEL TO ALUMINIUM

18:00 Transitioning from Steel to Aluminium for Structural Components, Castings & Extrusions - A Design-to-Manufacturing Approach

The move from steel to aluminium is always expensive as design and manufacturability are closely interrelated. So, what are the strategies for cost effective transition from steel to aluminium structures and parts to ensure commercial viability?

• Cost-effective application of aluminium
• A comparison between steel and aluminium applications in the a00utomotive industry is given from various points of view from design to manufacturing
• Conclusions and results

18:25 Questions & Discussion

18:30 End of the conference