SAE 2012 World Congress

Technical Session Keynotes

Chats with the Experts were designed to encourage small groups to explore subjects of interest to them, pose questions, and share ideas and practical solutions in an informal setting. The subject matter experts will provide brief opening statements on the topic to kick things off and will facilitate an interactive dialogue. Chats with the Experts will feature additional technology topics such as safety, powertrain controls, and hybrid and electric vehicles.


Challenges in Evaluating Fatigue Performance of Plastics and Composites
Jackie Rehkopf Jackie Rehkopf,Plasan Carbon Composites
(April 24; 1:00 PM)

Engineered plastics and composites are finding more use in structural and semi-structural components to achieve the industry's lightweighting needs. Along with their lightweighting attributes, they bring some challenges when it comes to evaluating their fatigue performance. Some of these challenges, that exist in both testing and data interpretation, will be discussed, along with a few examples.

What Steel Must do to Remain a Viable Automotive Materials
Bart Depompolo Bart Depompolo, US Steel
(April 25; 8:00 AM)

With the ever increasing safety and fuel economy regulations, the focus on environmental stewardship and the always present affordability issue, automakers are more challenged than ever before to choose their materials wisely. While steel is not a lightweight material, steel has been proven to provide affordable and significant lightweighting opportunities through the use of higher strengths and optimized design.

This talk will discuss how the steel industry must react to the challenges our automotive customers face as they develop their paths forward to meet future performance goals and government regulations through the 2025 timeframe. The auto and steel industries in North America have worked together for decades to identify the target properties of future steels, the product and manufacturing gaps that exist to achieve those targets and develop the solutions to maintain steels role in supporting a strong global automotive industry.

Graduate Western Michigan University - BS Metallurgical Engineering

Began working at National Steel, Great Lakes Steel Division Metallurgical Laboratory in 1973 while attending college. After graduation accepted a job at National GLS and worked in various quality control positions for nearly 10 years including product metallurgist, developmental metallurgist, and product quality manager. Moved to National's Product Application Center in 1982 and focused on automotive applications development. Spent 2 years as International Sales Manager. With the Unites States Steel purchase of National in 2003 Bart assumed his current position of Technical Marketing Manager in which he spends his time working with USS research, mills and customers to develop steels to meet future automotive needs. Bart also spends considerable time supporting the Steel Market Development Institutes Automotive Applications Council and the Auto Steel Partnerships Joint Policy Council as well as leading lightweighting project teams to forward the use of steel in future automotive applications.

Novel Local Structural Durability Concepts for Designing Welded Automotive Components
Thomas Bruder
Cetin Sonsino
Thomas Bruder, Fraunhofer Inst. For Structural Durability & System Reliability
Cetin Sonsino, Fraunhofer Inst. For Structural Durability & System Reliability
(April 25; 10:00 AM)

For analyzing the structural durability of welded joints various approaches are used. Recently, in the context of a joint research project, fatigue tests were performed by five German universities and institutes on welded components, welded parts of larger structures as well as component-like samples of weld details. The welding parameters for all test coupons and structures tested were chosen according to the industrial production process. Based on this data base, nominal, structural and notch stress approaches are analysed with regard to applicability and quality of assessment. Within the notch stress approach the actual weld geometry except the real notch radii can be taken into account. For the notch radii various fictitious values, the reference radii 0.05, 0.3 and 1 mm, are applied.Experimental and numerical results for welded steel components are presented.Furthermore, an outlook is given to an extension of the notch stress approach, which is based on an averaged stress value derived from the stresses in the notch ligament according to Neuber.

Emerging Technologies in Polymers and Coatings
Jamil Baghdachi Jamil Baghdachi, Eastern Michigan Univ.
(April 26; 1:00 PM)

Today's global economy, increased demand for energy, environmental impact and sustainability issues along with increased attention to quality of coatings materials necessitate a fresher look at the technology. To thrive amid ever-fiercer competition, and rapidly changing products, companies must innovate. Suppliers of raw materials and the coatings must focus on rational approaches to product development with emphasis on value-added goods. Such approaches are based on Emerging Technologies. Lean processes, judicial choice of multi-functional materials, reduction of waste and increasing efficiency and product durability both in formulation and manufacturing are the key factors in this approach.

Dr. Baghdachi is a Professor of Polymers and Coatings and the Director of Coatings Research Institute at the Eastern Michigan University. He joined the Coatings Research Institute in 1997, after spending 20 years at various technical and managerial capacities at BASF Corporation, DuPont, and ARCO Chemical Company. He received BS and MS degrees from the University of Tennessee and a Ph.D. from the University of Mississippi in 1982 and has conducted postdoctoral work at the University of Massachusetts, Amherst. He is the author/editor of 5 technical books in related areas and has published over 122 papers including seven book chapters and conference proceedings and holds 44 U.S and international patents. He is the Fellow of the American Chemical Society; the Vice Chair for the PMSE Division of the American Chemical Society, Chair, Science and Technology of the American Coatings Association.

Professor Baghdachi is an active industry consultant and has been consulted by over 200 clients globally and is a frequent speaker in professional technical societies and organizations both nationally and internationally. He has been organizing the Smart Coatings and Emerging Technologies symposiums since 2005. His current research interests include applied research and development in automotive/aerospace/industrial/adhesives fields and in smart and stimuli responsive, conductive, self-assembling, Nano composite materials, adhesion, and corrosion science and technology.


Vehicular Emissions in Review
Tim Johnson Tim Johnson, Corning
(April 24; 10:00 AM)
Thermal Systems for Electric and Hybrid Vehicles
Greg Major Greg Major, Chrysler LLC
(April 24; 10:00 AM)

Greg is the manager of Electrified Vehicle Thermal Systems in Chrysler Group LLC's e-Powertrain Systems. He is responsible for the definition of electrified vehicle thermal systems and for the development of battery thermal systems, power electronics cooling and electric motor cooling in electrified vehicles. He has more than twenty-five years of experience in the design and testing of thermal systems for hybrid, plug-in hybrid, fuel cell, and electric vehicles. His passion to innovate and create is demonstrated by his more than thirty patents. Greg has a Bachelor of Science in Electrical Engineering from Purdue University and a Masters of Business Administration from Case Western Reserve University.

Air Cooled Heat Exchanges - Past, Present and Future
Arif Khan Arif Khan, API Heat Transfer Inc.
(April 26; 8:00 AM)

Arif Khan has more than 20 years of experience in technical and management positions since obtaining a Ph.D. in mechanical engineering in 1990. He worked at Ford Motor Company / Visteon Automotive in various assignments developing high efficiency long life filter media for engine air induction systems, roll formed high performance multiport windowed refrigeration tubes in which two halves are brazed and simulation tools for predicting performance of compact air cooled heat exchangers like radiators, condensers and charge air coolers. He was extensively involved in employing state of the art 3D, transient CFD formulations and methodologies in simulating performances of primary heat exchange surfaces encountered in louver fins, offset strip fins and tubular heat exchangers. Since 2007 he has been Director R&D at API Heat Transfer, Buffalo, New York. API Heat Transfer is a multinational manufacturer of shell and tube, plate and air cooled heat exchangers. In his current role he has lead the efforts in multimillion dollar modernization of research laboratory and development of high performing heat exchangers.

Sustainable Manufacturing - Reducing Carbon Footprints and Environmental Impacts
Tom Murray, US EPA
(April 26; 8:00 AM)
Energy Efficiency and Sustainability for Productivity
Afif Bitar Afif Bitar, AAM
(April 26; 10:00 AM)

Afif M. Bitar joined American Axle & Manufacturing (AAM) in 1997 as a Senior Electrical Engineer at Detroit Gear & Axle. Prior to his current position, he served as a Corporate Facility & Construction Manager where he managed the construction of AAM's new facilities and equipment installation. In his current position, Bitar is responsible for managing infrastructure systems, energy contract negotiations, energy management and insurance loss prevention controls.

Prior to joining AAM, Bitar served as a Senior Technical Specialist at Duke Engineering & Services responsible for the design of various electrical projects associated with various nuclear power plants, commercial and government facilities.

Bitar holds a Master of Science degree in Electrical Engineering from the University of Michigan. He is a professional engineer in five states, a certified energy manager and a certified energy auditor. He is an active committee member of the Institute of Electrical and Electronics Engineers (IEEE), Association of Energy Engineers, and National Fire Protection Agency (NFPA).

Pathways to Improved Fuel Consumption
John J. Kasab John J. Kasab, Ricardo Inc.
(April 26; 1:00 PM)

The proposed rules for greenhouse gas emissions and fleet fuel economy that were recently issued by the U.S. government in coordination with the State of California covering the period of 2017-2025 are designed to significantly reduce fuel consumption across all types of light duty vehicles. At the fleet level, these rules represent a 50% reduction in fuel consumption by new vehicles in 2025 compared to current 2011 fleet levels. In parallel, global economic growth and development should continue to provide a strong demand for crude oil products, including fuels. Thus, the combination of regulatory push and market pull will therefore provide a strong impetus for light duty vehicles (LDV) to have significant improvements in fuel consumption over the next 5-15 years.

This presentation provides an overview of the technologies that will be incorporated into future LDV to help them meet the challenge of significantly improved fuel consumption targets. The focus of this paper is on the constituent technology packages describing major vehicle systems, such as powertrain configuration, engine, and transmission. Pathways from the current state of the art to expected future performance levels are described.

John Kasab is currently the Chief Engineer for Chemical Technology and Innovations at Ricardo, Inc.. He joined Ricardo in 2003, and has contributed his expertise in chemical engineering and computational simulation to a number of projects. Project areas include alternative fuels technology; emissions control system design and modeling; fuel cell system performance and development; hybrid and conventional vehicle performance simulation; engine performance; and technology roadmapping.

Prior to joining Ricardo, Inc., Dr Kasab was the founder and principal of Kasab Research, LLC, a small technical consultancy. He also worked for Scania CV AB at their main technical center in Sodertalje, Sweden, and at the Engine Research Center at the University of Wisconsin-Madison. Dr Kasab received his Ph.D. in Chemical Engineering from the University of Wisconsin-Madison, and a MS and BS cum laude in Chemical Engineering from Washington University in St. Louis. He is a registered Professional Engineer in the State of Wisconsin.


Engineering Safe Mobile Systems - The Omnipresent Challenge for Automotive Engineering
Graham Hellestrand Graham Hellestrand, Embedded Systems Technology Inc.
(April 24; 10:00 AM)

Graham Hellestrand is Founder and CEO of Embedded Systems Technology, Inc. (2007) - his 3rd start-up and the 2nd in Silicon Valley, both of which focus on systems engineering as appropriate for the automotive space. His 1st start-up was founded in 1973 while he was a PhD student and acquired in 1978. His 2nd start-up, VaST Systems Technology Corp., was founded in 1997, venture funded in 1998 and acquired by Synopsys in 2010. During 1983, he was principal consultant for an Australian company which successfully built the first 80186 & DOS based, battery operated, notebook computer - the Dulmont Magnum. From 1986-1989, he was Group Leader, Devices and Systems, CSIRO, Division of Information Technology; during 1988 he was R&D Executive at Ausonics Pty Ltd, an Australian ultrasound manufacturing company. From 1973-1998 he was a computer science & engineering academic at the University of New South Wales (UNSW) in Sydney, Australia and was appointed full Professor in 1989. During 1981-1996 he was also Director of the VLSI and Systems Technology Laboratory at that university. He is Emeritus Professor of Computer Science and Engineering, UNSW, a Fellow of the IEEE and Fellow of the Institution of Engineers, Australia. He is the principal author of two patents and has published in excess of 110 papers in international conferences and journals. From 2009 to present has been a member of the Australian Government's Information Technology Industry Innovation Council. He holds BSc(Hons), PhD and Exec MBA degrees from UNSW and an MBA from University of Sydney. He has held a number of Board and VP positions in IEEE CAS between 1994 & 2010. He has lived in Silicon Valley for the past 14 years

Challenges in Systems Engineering
John A. Thomas John A. Thomas, Booz Allen Hamilton Inc.
(April 25; 8:00 AM)
Systems Engineering Development Chain
Joseph Lomonaco Joseph Lomonaco, Harley-Davidson Motor Co.
(April 25; 1:00 PM)

Dr. Joseph Lomonaco, Manager - Advanced Controls & Model-Based Design, Harley-Davidson Motor Co., has been on the leading edge of automotive embedded systems for over a decade. His experience spans a wide range of modeling topics and includes work for Chrysler, Mercedes Research and Development, and most recently Harley-Davidson Motor Co. Dr. Lomonaco holds a Ph.D. in model-based control and optimization from Oakland University.

Extending Functional Safety Processes to Include Security Risk Assessment
David Ward David Ward, MIRA, Ltd.
(April 26; 1:00 PM)

Dr. David Ward is Head of Functional Safety at MIRA Limited, a leading independent provider of automotive engineering services. Dr. Ward is a recognized international expert in automotive functional safety and is the UK Principal Expert to ISO/TC22/SC3/WG16 - Road vehicles - Functional Safety - which has developed ISO 26262 as well as contributing extensively to the UK's MISRA initiative. Dr. Ward provides expert support, advice and independent assessment to clients developing safety-related electronic systems. His particular expertise includes "drive by wire" vehicle control systems and hybrid and electric vehicles.


Deterministic and Stochastic Optimization in Automotive Industry
Charles Yuan
Patrick Koch
(April 25; 1:00 PM)
Charles Yuan, Simulia

Charles is a senior engineer at SIMULIA. He joined SIMULIA in 2008 through the acquisition of Engineous Software, Inc., where he worked since 1996. He has been working in the Automotive and Aerospace industries on various projects such as optimization, multi-disciplinary optimization, multi-objective optimization, and robust engineering. He also teaches an Isight class monthly in the Great Lakes office. Charles studied Mechanical Engineering at Virginia Tech and received his Master and Bachelor degrees in Engineering from Tsinghua University, Beijing, China.

Patrick Koch, Simulia

Patrick Koch manages a development team within the Simulation Lifecycle Management (SLM) R&D organization at SIMULIA. Patrick leads the release team for the Isight and SIMULIA Execution Engine products. He and his team are specifically responsible for the development, implementation, and application of engineering design methods, post processing and visualization tools, client interfaces, and distributed computing technologies. His specific area of interest is probabilistic quality engineering methods, including design of experiments, robust design optimization, design for six sigma, reliability-based design, Taguchi methods, and surrogate modeling techniques. Patrick is responsible for the introduction of these technologies into the original iSIGHT product line during his 10 year tenure with Engineous Software, Inc. Patrick received his Ph.D. in Mechanical Engineering from Georgia Institute of Technology in 1998.

Report of the Annual Electric Vehicle Safety Standards Summits
Casey Grant Casey Grant, Fire Protection Research Foundation
(April 26; 8:00 AM)

This presentation provides an overview of the U.S. National Electric Vehicle Safety Standards Summits held in Detroit MI in October 2010 and again in September 2011. These events were co-hosted by NFPA and SAE, with the purpose of developing and reviewing the on-going progress of an action plan for the safe implementation of electric vehicles using safety standards. The initial Summit focused on establishing cross-stakeholder dialogue, identifying the applicable fire and electrical safety codes and standards, identifying knowledge gaps, and clarifying the path forward to address these gaps. The subsequent Summit facilitated further networking dialogue, reviewed the progress made since the previous Summit, further clarified relevant codes and standards needs, and refined the previously established action plan. The key topic areas of vehicles, built infrastructure, emergency responders, and support services have provided the general framework for addressing this overall topic.

Mr. Grant is the Research Director for the Fire Protection Research Foundation, a non-profit organization that works with the National Fire Protection Association as its research affiliate. His responsibilities include oversight for the multiple research projects in support of the Foundation's mission to plan, manage and facilitate research on behalf of the NFPA mission to make the world safer from fire and related hazards. Casey holds a Bachelor of Science degree from the University of Maryland and a Master of Science degree from Worcester Polytechnic Institute, both in Fire Protection Engineering. Casey is a Registered Professional Engineer in Fire Protection Engineering in the states of California and Tennessee, and is a member of both the Beta and Gamma Chapters of the Salamander Fire Protection Honorary Society. Casey is a Fellow of the Society of Fire Protection Engineers, and has one fire protection related U.S. patent. He has given numerous presentations on fire safety around the world, and is a member of the USA Branch of the Institute of Fire Engineers. Prior to joining the Research Foundation in 2007, Casey was the Secretary of the NFPA Standards Council and Assistant Chief Engineer, where his responsibilities included oversight for the approximate 300 NFPA codes and standards.

SAE Standards Update - Safety and Human Factors Committee Activities
Daniel Selke, Mercedes-Benz
(April 26; 8:00 AM)
SAE Ground Vehicle Standards - Update on Activities
Brian Everest Brian Everest, General Motors
(April 26; 8:00 AM)

Mr. Everest has twenty-eight years in the auto industry, twenty-three with General Motors. He is a Senior Consultant & Manager within GM's Interior and Safety Department. His duties involve managing the Airbag and Crash Reconstruction Group, providing engineering analysis of the field performance of vehicle restraint systems & air bags, and assisting General Motors Legal Staff in the technical assessment of airbag claims. He has experience using EDR field data since 1996. Previous duties as part of GM's Electrical Center included implementing trends and new technology in occupant controls for future vehicles, designing and programming component test devices, assessing the effects of accelerated pollutant exposure on electrical components, and performing competitive assessment for occupant controls.

Mr. Everest has been an SAE International member for 16 years. He was a member of the Vehicle Event Data Interface Committee and currently Chairs the Event Data Recorder Committee. Within that committee he Chairs the Electronic Control Unit Task Forces and participates on the Update J1698 and Future Parameters Task Forces.


Lightweight Structure Development and Optimization Process for Vehicle Electrification
Simon Xu Simon Xu, General Motors Company
(April 24; 10:00 AM)

Simon Xu is Engineering Group Manager for Vehicle Optimization Methods at General Motors Technical Center in Warren, MI and is responsible for innovations in virtual vehicle development process, tools and strategies. Simon is an acknowledged expert in advanced optimization techniques such as morphing, topology optimization and multi-disciplinary optimization. Through his efforts and influences, GM's virtual vehicle development has been continuously improved by the implementation of new tools and processes with benefits in vehicle performance, mass, cost and fuel economy. He has also played a major role in GM's advance technology programs which developed new electric and hybrid vehicle concepts and the optimal use of alternative light weight materials for future vehicle programs. He chairs the GM global Optimization Focus Group and authorizes the publications of GM corporate standard work guidelines on optimization methods. He holds one patent on an advanced vehicle frame design and numerous internal GM records of inventions.

Concepts and Future Perspectives of Hydrogen IC Engines
Helmut Eichlseder Helmut Eichlseder, Graz University of Technology
(April 25; 9:00 AM)

Helmut Eichlseder was born in Steyr, Austria. He received the Master's degree in mechanical engineering in 1984 and the Ph.D. degree in 1989, both from Graz University of Technology, Austria. He joined BMW's Diesel Development in Steyr, Austria, in 1990, working then in pre- and series development where he was responsible for performance, fuel efficiency and emissions of a new DI Diesel engine family of 4, 6, and 8 cylinder engines until start of production. From 1997 to 2001, he was responsible for Alternative Combustion Systems and DI Gasoline Engines in the Gasoline development unit of BMW in Munich. In April 2001, he became Professor for Internal Combustion Engines at TU Graz. His research interests include combustion system development, alternative fuels, emission reduction, and thermodynamic systems. The results were published in some books (Gasoline Engine Technology, Hydrogen in Vehicle Technology), book chapters (Gasoline Direct Injection), and more than 100 articles.

Dr. Eichlseder is Head of the Institute for Internal Combustion Engines and Thermodynamics at Graz Tecnical University since October 2002.

Natural Gas LD Vehicles: Traveling the Distance and the Road Ahead
Dick Kauling Dick Kauling, General Motors of Canada
(April 25; 1:00 PM)

Brief overview of some of the technical challenges associated with bringing natural gas light duty vehicles to market. Presentation will touch on the impact of infrastructure, product features, performance attributes and customer expectations with a focus on powertrain considerations in a global context.

Dick Kauling is currently the Engineering Manager for the Gaseous Fuel Technical Resource Centre, part of GM's Powertrain engineering organization, located in Oshawa, Ontario, Canada.
He is activity working on and supporting many of GM's global compressed natural gas (CNG) and liquid petroleum gas (LPG) applications.

Dick had previous responsibly to manage all the vehicle electrical and controls activity as part of GM's Canadian Regional Engineering Centre (CREC) as well as responsibilities in overseeing CREC's Pre-production, Computer Aided Engineering. Tests & Validation, Laboratory and Kapuskasing Cold Weather Development Centre activities. During that time period, he was actively involved in ensuring the successful Oshawa assembly of the 100 Chevrolet Equinox Fuel Cell vehicles as part of GM's Project Driveway program and ensuring hydrogen refueling capability in Kapuskasing

Prior to that assignment, Dick was overall design and engineering execution responsible for all North American CNG and LPG vehicle programs for vehicles sold from 1997 to 2006. Dick has extensive experience in chassis powertrain mounting for North American front wheel drive applications, experience in powertrain design integration and production launch, and worked on a previous Canadian Players Challenge Motorsports program. Dick started his 30 year career at GM as an engine calibration and development engineer working on various engine and vehicle programs. Dick earned his Bachelor of Applied Science in Mechanical Engineering degree from the University of Waterloo in 1983.

Introduction of EcoCar the Next Challenges Year Three Vehicle Refinement and Testing
Patrick M. Walsh
Brian Benoy
Kristen De La Rosa
(April 26; 3:40 PM)
Patrick M. Walsh, Argonne National Lab.

Patrick Walsh serves as the Advanced Vehicle Testing and Controls Engineer at Argonne National Laboratory and a key organizer for EcoCAR 2. Patrick graduated with his master's degree from Virginia Tech after serving as the team leader for the EcoCAR team (Hybrid Electric Vehicle Team of Virginia Tech) for two years. Prior to graduate school, Patrick worked as a powertrain analyst and calibrator at BMW in Greenville, South Carolina as a co-op during his undergraduate work at Virginia Tech. For EcoCAR 2, Patrick will serve as the event captain for the Emissions and Energy Consumption event, as well as support controls and simulation activity. When Patrick is not working for AVTC's directly, he will be working in Argonne's Advanced Powertrain Research Facility, testing and reporting on advanced technology vehicles.

Brian Benoy, Argonne National Lab.

Brian Benoy is the Advanced Vehicle Technology Competition (AVTC) Controls & Simulation Engineer at Argonne National Laboratory. Brian currently holds a bachelors of science in electrical engineering from Kettering University, and will complete his masters of science in electrical engineering from Mississippi State University in August of 2012. As a graduate student in the AVTC program during EcoCAR: The NeXt Challenge, Brian gained valuable leadership and technical experience as the controls team leader for Mississippi State University.

Kristen De La Rosa, Argonne National Lab.

Kristen De La Rosa is director of the Advanced Vehicle Technology Competition (AVTC) program at Argonne National Laboratory, where she has organized more than 18 competitions since she started in 1997. Serving as a sponsor or key organizer for 20 of the 28 AVTC competitions in the program's history, Kristen has been at the forefront of defining, executing and growing the program for almost 16 years and is responsible for the managing all day-to-day activities of the current EcoCAR 2: Plugging In to the Future series. She is also responsible for establishing and managing the program's multi-million dollar sponsorship & fundraising efforts. Kristen graduated from the University of Texas at Austin with a BBA in Business and Communications.