DAY 1 – COST COMPETITIVE MULTI-MATERIAL SELECTION AND UTILIZATION

Evaluate The Design Advantages Of Alternate Lightweight Materials As A Solution To Escalating Costs & Supply Chain Sourcing Challenges Cost Competitive Material Selection & Design For Manufacturability

0850 Chair’s Opening Remarks For The Main Conference

KEYNOTE PANEL – REDUCING THE COST OF PRODUCING VEHICLES UTILIZING LIGHTWEIGHT MATERIALS

09:00 Utilizing Alternate Materials & Substitute Processing Of Existing Materials To Address Supply Chain Shortfalls & Reduce Cost

In 2022, cost continues to be a major strategic driver for the industry to ensure that the next generation of lightweight vehicles are profitable for OEMS and affordable for customers. For example, certain grades of aluminium and magnesium are increasingly challenging from a supply chain and cost perspective. Solutions include utilizing alternate materials for specific applications and applying different processes to existing materials to make the vehicle lighter incorporating, for example, new additive materials together with innovative sandwich applications. The purpose of the opening panel is to focus on the architectural decisions that can be made in terms of the manufacturing processes and availability that support the materials. How are OEM’s and supply- chain partners tackling this, across the board?
 

COST REDUCTION - MIXED METAL DESIGNS

Design Of Chassis & Underbody, Considering Manufacturability & Utilizing Materials That Are More Cost Effective & Readily Available (25 minutes)

Ashwin Ramesh BiW Launch Engineer - Skateboard Canoo

MIXED METAL MATERIAL SELECTION FOR BODY STRUCTURE, REINFORCEMENTS AND UNDERCARRIAGE

Substituting Expensive Grades Of Aluminium With Cheaper, Lightweight Alternatives For Specific Zones Of The Body Structure (25 minutes)

Dr. Lei Shi Chief Technology Officer Nuola Auto Global R&D, Nuola Auto

WHERE DOES IT MAKE SENSE TO USE ULTRA HIGH STRENGTH STEEL OVER ALUMINUM IN MIXED METAL DESIGNS?

Optimal Application Of Ultra High Strength Steel And Aluminium Throughout The Body Structure Considering Crash Safety, Cost, Manufacturability & Joining Technology Selection (25 minutes) 

EXAMPLE APPLICATIONS	EXAMPLE MATERIALS	CONSIDERATIONS (APPLY TO ALL)
Body In White & Chassis	Ultra-High Strength Steel	Cost
A-Pillars, B-Pillars Side Impact Beams	Advanced High Strength Steel	Manufacturability
Passenger Safety Cage Components	Pure Aluminium	Sustainability & Circular Economy
Reinforcements	High Strength Corrosion Resistant Aluminium	Galvanic Corrosion
Automotive Body Components	6061 and 3003 Series Aluminium	Lightweight Properties
Suspension & Wheels	Reinforced Composites	Strength
Battery Attachment & Enclosure (BEV)	Smart Sandwich Materials	Ease Of Joining
BEV & Thermal Integration Components	Magnesium	Crash Protection Advantages
Body Shell	New Innovations	Supply Chain Availability

 

10:15 Curated Questions & Discussion

 

10:30 Networking Morning Coffee Break

 

PANEL – THE NEXT GENERATION OF ALTERNATE MATERIALS INNOVATION FOR AUTOMOTIVE

11:00 Evaluate Alternate Lightweight Materials, Considering Manufacturability, To Make Vehicles Lighter & More Sustainable, Potentially At Reduced Cost

AEROSPACE AND MILITARY GRADE REINFORCED COMPOSITES

Transferable Lessons From Aerospace & Military Evaluating The Potential Application Of Reinforced Composites For The Passenger Compartment & Internal Panels (20 MINUTES)

• Assessing material properties and key applications
• Considering cost, manufacturability and sustainability

NATURAL FIBER COMPOSITES

Addressing The Manufacturability Of Using Natural Fibre Composites To Reduce Vehicle Weight (20 minutes) 

Dr.Omar Faruk Sr. Research & Development Engineer Ford Motor Company

NEXT-GENERATION THERMOPLASTIC COMPOSITES

Investigating Lightweight Long Fibre Thermoplastic Composites For Applications That Require Resistance, Rigidity, Recyclability & Efficient Manufacturing Methods (20 minutes)  

12:00 Curated Questions & Discussion

 

12:20 Networking Lunch Break In The Exhibition Showcase Arena 

 

APPLICATION AND MANUFACTURING CONSIDERATIONS OF CARBON FIBRE

13:00 Understanding The Thought Process Behind and Issues Affecting Optimum Material Selection for High-End Performance Vehicles

• Considering material weight, cost and availability

• Analysis of the effectiveness of select materials including Carbon Fibre, Titanium and Aluminium
• Material selection for whole vehicle architecture  

Jason Liang, Director of Manufacturing, Hennessey Performance

13:25 Questions & Discussion

 

UNDERSTANDING THE APPLICATION OF AHSS AND UHSS

13:35 Cost Effective Utilization Of UHSS & AHSS To Replace Aluminium For The Body In White, Chassis, Closures & Fasteners 

• Reviewing the business case for high yield strength steels
• Clarifying the advantages of these materials
• Optimal selection for specific component manufacturability
• Future considerations for material development

14:00 Questions & Discussion

 

ULTRA HIGH STRENGTH STEEL & GEN 3 MATERIALS

14:10 Application Of Ultra High Strength Steel For Body, Chassis, Underbody & Suspension

• Practical considerations of designing with ultra high strength steel
• Highlighting optimal material selection and overcoming design challenges
• Addressing scaling up considerations

Louis G. Hector, Jr., Ph.D. Battery Cell Systems Research GM Global Technical Center

14:45 pm Questions & Discussion

 

UNDERSTANDING DESIGNING WITH HIGH-STRENGTH STEELS

14:55 Design For Manufacturability & Sustainability Whilst Reducing Cost, With The Latest Materials Including Ultra High Strength Steel

Shripadraj Ponkshe General Manager, Head of Material Engineering Tata Motors

15:20 Questions & Discussion

15:30 Afternoon Refreshment Break

COST-EFFECTIVE APPLICATION OF ALUMINIUM IN MIXED METAL DESIGNS

16:00 Keeping Costs Low When Designing With Aluminium In Mixed Metal Designs – How To Deliver Weight Savings For Cast, Sheet & Extrusion Applications

• Market outlook evaluating the advantages of the latest aluminium grades and supply chain availability
• Optimal technical and cost-effective solutions for specific models and volume requirements
• Cost effective mixed metal design concepts that utilize aluminium
• Sustainability and recyclability

16:25 Questions & Discussion

 

PANEL – CORROSION MITIGATION STRATEGIES IN MIXED METAL DESIGNS

16:35 Addressing Corrosion Mitigation In Mixed Metal Designs Through Simulation & Coatings Innovation 

 

MIXED MATERIAL CORROSION MITIGATION Using Numerical Simulation To Predict & New Coatings Technologies To Mitigate Galvanic Corrosion Behaviour Due To Complex Electrochemical Factors In Mixed Material Body In White Designs (20 minutes)

 

MAGNESIUM CORROSION Cost Competitive Surface Coatings For Magnesium Alloys In Mixed Metal Designs (20 minutes)

 

CARBON FIBRE AND METALS Finding Solutions To Mitigate The Influence Of Galvanic Corrosion Between Carbon Fibre Reinforced Polymers & Metals (20 minutes)   

17:35 Curated Questions & Discussion  

BENCHMARKING SUSTAINABLE LIGHTWEIGHT MATERIAL SELECTION & COST EFFECTIVE END OF LIFE RECYCLING “How Can The Industry Move From 20% To 95-100% Recycling?”

SUSTAINABLE LIGHTWEIGHT MATERIALS 

17:55 Selection Criteria Of Sustainable, Lightweight Metals For Specific High Strength Body Structure Applications – Which Sustainable, Lightweight Material For Which Part? 

OEMs and their supply chain partners explore the roadmap ahead to improve the sustainability of third generation steel and aluminium.

 

CASE STUDY 1 Future Pathways On The Cost Effective Recycling & Reproduction Of Sustainable, Lightweight Aluminium – (20 minutes)

Manoj Garg Deputy General Manager Tata Motors

 

CASE STUDY 2 Evaluate The Future Sustainability Of Third Gen Steel In A Circular Economy –(20 minutes)

18:35 Questions & Discussion

18:45 Chair’s Closing Remarks & Close Of Day 1

Evening Drinks Reception In Exhibitors Area For All Attendees