Innovative Joining Techniques for High-Strength Applications and Battery Housing Assembly with Scalable Advanced Manufacturing Technologies

09:20 Chair’s Opening Remarks

Kaushlendra Singh Manager, Dimensional Management & Structural/NVH CAE PACCAR

OPENING KEYNOTE – CAPITALIZING ON EMERGING JOINING AND MANUFACTURING TRENDS

09:30 INNOVATIONS IN SIMULATION AND MODELLING FOR OPTIMIZATION OF JOINTS Advanced Material Modelling For Optimization Of Accurate Prediction Of Joint Design Durability

Integrating advanced material modeling and AI-driven optimization is revolutionizing the prediction of joint design durability in automotive applications. This session will explore cutting-edge techniques for accurately modeling and simulating the performance of joints under various loading conditions, enabling the optimization of joint design for enhanced durability and reliability.

-  Understand the latest models and simulations for simulating joint performance under various loading scenarios
-  Explore the benefits of combining different simulation scales (micro, meso, and macro) and incorporating multi-physics phenomena, such as thermal and mechanical loading, to achieve a comprehensive understanding of joint performance in complex applications
-  Learn from successful implementations of advanced material modeling in the automotive industries, illustrating how these techniques can be applied to improve the durability and reliability of joint designs in safety-critical components

Jose Luis Galaviz Frames Technical Lead Chassis Group Stellantis

10:10 Extended Questions and Discussion

JOINING METHODS INNOVATION TO MAINTAIN OVERALL STIFFNESS AND STRENGTH 

10:20 Optimizing Joining Techniques And Surface Preparation To Account For Different Surface Characteristics Of Composites In High Strength Body In White Applications 

-  Optimizing surface preparation for achieving a strong bond between composite materials cleaning, abrading, or applying a surface treatment, such as plasma or corona treatment
-  Choosing joining techniques that are compatible with the specific materials being used to prevent material degradation or weak bonding
-  Selecting a joining technique that provides adequate strength for the intended application, considering factors such as mechanical, thermal, and environmental loads
-  Using joining techniques that can accommodate different coefficients of thermal expansion, which can lead to stress at the joint during temperature changes these differences, such as flexible adhesives or mechanical fasteners that allow for some movement
-  Opting for joining techniques that offer moisture and corrosion resistance to ensure proper surface preparation to minimize moisture-related issues

Dr. Lei ShiChief Technology Officer Nuola Auto Global R&D Nuola Auto Co., Ltd.

11:00 Extended Questions and Discussion

11:10 Morning Refreshment Break

11:40 Deep Learning Empowered Design for Manufacturability Tools for Stamping Automotive Panel Components

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

12:10 Questions and Discussion

12:30 – 13:30 Lunch and Networking

ROUND TABLE DISCUSSION GROUPS

OPTIMAL JOINING TECHNIQUE SELECTION FOR MULTI-MATERIAL CRASH SAFETY STRUCTURES
13:30 Innovative Approaches to Joining Crash Safety Structures: Enhancing Performance and Integrity

13:30 Table1: JOINING SIDE IMPACT STRUCTURES AND THE POTENTIAL FOR JOINING STEEL & COMPOSITES
Optimize Cost Effective Joining Of Steel & Composites In Side Impact Structures & Address Key Manufacturing Process Challenges

This session focuses on optimizing the joining of steel in side impact structures, addressing key manufacturing process challenges critical to enhancing vehicle safety and performance. Gain insights into the latest advancements in joining technologies, material compatibility, and process control that ensure the successful integration of steel in side impact structures.

- Advanced joining technologies: Discover the latest joining techniques for steel, including friction stir welding, laser welding, adhesive bonding, and mechanical fastening, and their effectiveness in addressing the challenges associated with side impact structures
-  Understand the unique properties of steel and how to ensure compatibility with other materials in side impact structures, optimizing joint performance, durability, and structural integrity
- Explore the best practices for controlling and optimizing the joining process for steel in side impact structures, including real-time monitoring techniques, advanced non-destructive testing methods, and robust quality assurance procedures
- Addressing key manufacturing processes challenges, such as material degradation, heat-affected zones, galvanic corrosion, and process variability, to ensure the successful integration of steel in side impact structures

Table2 : FRONT-END AND REAR-END STRUCTURES – JOINING AHSS & ALUMINUM Optimal Joining Techniques For Combining AHSS With Aluminium To Allow For Weight Reduction While Maintaining The Required Structural Strength And Crash Safety Performance             

This session examines the optimal joining techniques for combining Advanced High-Strength Steel (AHSS) with aluminum to reduce weight while maintaining structural strength and crash safety performance. The session compares the cost and performance benefits of three joining techniques: friction stir welding (FSW), high-precision laser brazing, and adhesive bonding.

14:00 Group Feedback and Questions

14:10 Table1: OPTIMAL JOINING TECHNIQUES FOR ROOF STRUCTURES & ROLLOVER PROTECTION Innovations in Multi-Material Joining Techniques for Enhanced Rollover Protection in Automotive Roof Structures

For rollover applications, it is crucial to create strong, durable, and lightweight joints between materials to ensure structural integrity and passenger safety. In this session, we will explore the latest innovations in multi-material joining techniques for creating roof structures with improved rollover protection.

• Evaluate the cost of the innovative joining technology compared to more traditional methods, considering factors such as equipment, labor, and maintenance
• Ensuring the joining process is well controlled to achieve consistent, high-quality joints
• Implementing robust quality control measures, including inspections and non-destructive testing, to ensure joint integrity
• Assess the scalability of the innovative joining technology, as well as its compatibility with existing manufacturing infrastructure and processes
• Consider the environmental implications of the innovative joining technology, such as energy consumption, waste generation, and emissions

Table2: JOINING MULTI-MATERIAL FRONT AND REAR COLLISION SAFETY APPLICATIONS Advancing Joining Techniques For Integrating Thermoplastics, and Eco-Friendly Materials for Bumpers, Crumple Zones, and Front and Rear-End Collision Safety

• Conducting thorough material research and testing to ensure compatibility and optimize the selection of joining techniques
• Utilizing advanced joining techniques like adhesive bonding, mechanical fastening, ultrasonic welding, or induction welding, depending on the specific application and material combination
• Establishing stringent process controls and quality assurance protocols, including real-time monitoring and feedback systems, to maintain consistent joint quality
• Performing cost-benefit analysis and pilot projects to evaluate the feasibility of implementing advanced joining techniques in large-scale manufacturing environments
• Select joining techniques that facilitate disassembly and recycling, such as mechanical fastening or reversible adhesive bonding Consider using eco-friendly materials with established recycling channels

15:00-15:30 Afternoon Refreshment Break

JOINING BATTERY ELECTRIC HOUSINGS AND STRUCTURAL COMPONENTS

15:30 Table1 BATTERY HOUSING AND COMPONENTS Innovations in Joining Multi-Materials for Battery Housing and Structural Components

- Implement stringent process controls and quality assurance protocols, including real-time monitoring and feedback systems
- Incorporating thermal management considerations into the design and selection of joining techniques
- Optimizing material combinations and joining techniques to achieve weight reduction without compromising structural integrity
- Performing pilot projects and cost-benefit analyses to evaluate the feasibility of implementing advanced joining techniques in large-scale manufacturing environments

Table2 JOINING MULTI-MATERIALS FOR THE BATTERY HOUSING BASEPLATE WITH THE BIW Optimize Joint Design And Choose Suitable Joining Techniques That Provide Strong, Rigid Connections For Joining The Battery Housing Baseplate To The Floor & Body In White

-  Ensuring compatibility between materials such as aluminum, steel, and composites in the battery housing baseplate and the BIW is crucial to prevent problems such as galvanic corrosion and weak bonds
-  Optimize joint design and choose suitable joining techniques that provide strong, rigid connections, such as resistance spot welding, adhesive bonding, or mechanical fastening methods like self-piercing riveting
-  Vibration and noise control - Incorporating damping materials and design considerations to minimize vibrations and noise transmission through the joints between the baseplate and BIW
-  Optimize material combinations and joining techniques to reduce weight without compromising structural integrity, focusing on techniques such as adhesive bonding or friction stir welding
-  Use suitable surface treatments, coatings, or isolating materials to prevent direct contact between dissimilar metals and reduce the risk of galvanic corrosion

Table3: DESIGN FOR JOINING END-OF-LIFE - REVERSIBLE JOINING FOR BATTERY ENCLOSURES AND SYSTEMS Choosing Reversible Joining Techniques, Such As Mechanical Fastening Or Reversible Adhesive Bonding, To Allow Easy Assembly And Disassembly Without Compromising Structural Integrity

- Evaluating various reversible joining techniques and their applicability for the specific design requirements of battery enclosures and systems, considering factors such as cost, manufacturing scalability, and long-term reliability
-  Using modular design principles and standardized connections to enable efficient disassembly while minimizing the use of permanent joining methods, such as welding or traditional adhesive bonding
-  Designing battery enclosures and systems with materials that can be easily separated and recycled at the end of the vehicle's life
-  Ensuring that the reversible joining techniques maintain the required performance and durability throughout the vehicle's lifetime.
-  Performing long-term testing and durability studies to evaluate the performance of the reversible joining techniques under various operating conditions.

16:00 Group Feedback and Questions

16:10 Chairs Closing Remarks and Close of Day 3