Automotive Composites Technology Engineering Academy New!
Duration: 5 Days
Upcoming open enrollment dates being scheduled. Please check back.
Hotel & Travel Information
After more than 40 years of promise, the next decade will see an explosion in the use of composite materials. Aerospace and general aviation have been using the technology for years and automotive and alternative energy markets are now on the cusp of broader implementation. Car manufacturers are already implementing and launching carbon fiber composite development programs and working with both domestic and foreign producers of carbon fibers and composites. With the significant weight savings associated with composites, it is essential for automotive engineers to become knowledgeable about this technology which may revolutionize the way carbon fiber is used in automobiles and ultimately be instrumental in meeting government mandates for fuel economy.
This course will provide an overview of different composite materials in terms of material types such as carbon, glass and natural fibers. The focus, however, will be on carbon fiber processes, typical applications, benefits and shortcomings and limitations. Participants will become familiar with different composites terminology, quality issues, costs and automotive market needs and will gain a holistic understanding of automotive carbon fiber applications.
Learning Objectives
By attending this course, you will be able to:
- Describe the benefits of composites technology in automotive weight savings applications
- Choose composites manufacturing processes that can influence quality
- Identify engineering modeling methodologies for composite material and structural performance
- Specify common methods for characterization of anisotropic composite materials
- Evaluate the latest developments in non-destructive test methods for composite materials and structures
- Identify and contrast damage and crush characteristics for composites vs. metals
- Identify assessment approaches to durability in composites
- Identify recent developments and applications of composites in the automotive industry
- Summarize the opportunities for weight savings with composites
Who Should Attend
This course is designed for OEM, Tier I and Tier II supplier automotive engineers who are involved in developing weight savings solutions through composite materials innovations and wish to have an awareness of composite material vehicle technology applications. Engineers in manufacturing, design, analysis, advanced engineering, cost reduction, test, and research will benefit from the comprehensive nature of the course.
Prerequisites
An engineering degree is highly recommended, but not required. This Academy does not cover many of the basic concepts and assumes that the attendee already understands such concepts (stress, strain, viscosity, heat transfer, materials properties, vibration, impact, etc). Individuals who are transitioning to application of composite materials in light weighting automotive platforms will find this Academy particularly helpful.
Topical Outline
Monday
Market and Technology Needs for Composites - Dr. Siavoshani
- Diversity of applications of composites-aerospace, wind turbine, pressure vessels, oil and gas offshore, civil infrastructure
- Market trends and predictions
Light Weight Materials Technology Options in the Automotive Industry - Dr. Warren
- Candidate materials for light-weighting a vehicle
- Advantages, disadvantages, and major obstacles of each material
- Past development efforts in the Industry
- Current uses of advanced materials for weight reduction
DOE Automotive Composites Materials Program - Dr. Warrren
- Program Overview
- Current Industry Composite Car Development Efforts
Designing Carbon Fiber Composites for Cars - Guest Speaker: Dr. Anand Rau, Toray Carbon Fibers America
Composite Materials: Fibers and Polymers - Dr. Pipes
- Polymers: thermoset and thermoplastic
- Fibers: carbon, glass, Kevlar, Spectra
- Material forms: continuous fibers, LDF, fabrics, braids, short fiber
- Fiber orientation and collimation
- Fiber orientation in molding flow
- Fiber placement systems
- Draping conformation
Composite Processing Demonstration - Dr. Pipes
- Fabric draping
- Vacuum assisted resin transfer molding
- Microstructural analysis
Tuesday
Introduction to Composites Manufacturing - Dr. Pipes
- Prepreg technology
- Infusion molding-RTM, VARTM
- Compression molding
- Pultrusion
- Injection molding LFT
Processing of Composite Materials - Dr. Poursartip
- Introduction to composites process simulation
- Typical modeling and simulation frameworks
- Characterizing the system including materials response
- Simulating thermal management
- Simulating infusion
- Simulating porosity and voids
- Simulating residual stress and deformation
- Application to realistic problems: thermal management case study
- Application to realistic problems: quality management case study
- Application to realistic problems: dimensional management case study
- Summary and guidance for the effective use of simulation in practice
Wednesday
Composite Materials and Structures Performance - Dr. Zavattieri
- Micro-mechanics - composite properties from fiber and resin
- Macro-mechanics - effective composite properties
- Failure theories, cohesive zone models, fracture mechanics
- Finite element methods for composites
- Element choices and benefits
- Damage modeling
- Adhesive joints modeling
Crashworthiness Modeling of Composites - Xinran (Sharon) Xiao
- Explicit finite element analysis
- Composite material models in commercially-available explicit finite element codes
- LS-DYNA
- ABAQUS Explicit
- ALTAIR RADIOSS
- ESI PAM-CRASH
- Crash simluation ABC
- Simulations of impact of composite body panels
- Simulations of axial crush of primary energy absorbing structures
- Determine damage parameters using optimization based inverse methods
- User material models
Composite Materials Characterization - Dr. Pipes
- Fiber volume fraction and micro analysis
- Tensile and compression tests - strength, Young's moduli and Poisson's ratio
- Shear test methods - shear modulus and strength
- Flexural strength and stiffness
- Off-axis tension test - biaxial strength
- Coefficients of thermal expansion
- Laminate strength and modulus
- Open-hole tensile strength
- Mode I and Mode II fracture toughness
Wednesday Evening - Composites Computer Simulation Software Demonstrations
Join us for dinner and a special session of hands-on demonstrations of various simulation software programs for composites.
Thursday
Non-destructive Inspection and Evaluation of Composite Materials and Structures - Dr. Adams
- Common composite material damage mechanisms
- Non-destructive measurements and their sensitivities to common damage mechanisms
- Material health monitoring and prognostic measurements
- Nondestructive inspection technologies
- Case studies of nondestructive inspection methods
- Interactive real time demonstrations of inspection methods
Durability - Dr. Mallick
- Fatigue durability
- Designing against fatigue
- Crash durability
- Designing against crash
Joining Technology - Dr. Mallick
- Mechanical joining for composites - fasteners, design, strength
- Adhesive joining - adhesives, analysis and design
- Joining with metals - special considerations
Friday - Durability and Automotive Composites Case Studies
Crush Damage and Modeling of Structural Energy Absorption - Dr. Shahwan
- Energy management and the concepts of energy absorption
- Major distinctions between energy absorption mechanisms in metallic and fiber-reinforced polymeric (FRP) composites
- Modes of damage initiation, progression and failure in FRP composites
- Types of composites and their signature behaviors
- Computational considerations for crash (modeling, simulation, and prediction)
- Damage theories: limitations and range of applicability
- Explicit and implicit solvers for phenomenological and physics-based models
- Discretization and the dynamic coupling between local geometry and material
- Representative material volume, and limitations of common homogenizations
- Material scale, modeling scale and size effects on nominal strength
- In-Situ properties vs. estimated average (and bulk) properties
Challenges, Future Trends in Analysis, and Recent Demonstrations - Dr. Shahwan
- Modeling the manufacturing process
- Modeling of in-service/environmental effects on long-term performance
- Damage repairability, repair technologies and the lurking challenges
- Integrated computational materials engineering (ICME): is it needed, and why?
- The hierarchical (sequential) analysis (modeling input)
- Automotive model for pre-competitive collaboration on advanced research
- The Automotive Composites Consortium (ACC), USCAR, and the US-DoE
- ACC's energy management and modeling projects: portfolio of advancements
- ACC's demonstration projects
Lessons Learned in the Composites Academ - Drs. Siavoshani & Pipes
- Summary of the lessons learned
- Framework for future progress
Instructor(s): R. Byron Pipes, Saeed Siavoshani, Doug Adams, Pascal Hubert, Gary Lownsdale, Pankaj K. Mallick, Anoush Poursartip, Khaled Shahwan, Dave Warren, Xinran (Sharon) Xiao, Pablo Zavattieri
R. Byron Pipes – Lead Academy Instructor
Dr. Pipes is the John L. Bray Distinguished Professor of Engineering at Purdue University and has been a member of the National Academy of Engineering since 1987. His prestigious academic career includes service as President of Rensselaer Polytechnic Institute and Director of the Center for Composite Materials at the University of Delaware. In his early career, he worked in composites development for General Dynamics Fort Worth (now Lockheed.) Dr. Pipes is an international expert recognized for his outstanding scholarship in the field of polymer composite materials in the areas of advanced manufacturing science, durability, design and characterization and for his leadership in creating partnerships for university research with the private sector, government and academia. He is the author of over one-hundred archival publications including four books and has served on the editorial boards of four journals in his field. He holds Fellow rank in ASC, ASME and SAMPE and is a registered professional engineer in the State of Delaware. Dr. Pipes received a Ph.D. in Mechanical Engineering from the University of Texas at Arlington and a M.S.E. from Princeton University.
Saeed Siavoshani – Industry Advisor
Dr. Saeed J. Siavoshani is currently a Principal Research Scientist at the Dow Chemical Corporation and is also an adjunct professor at the University of Detroit Mercy where he teaches a comprehensive electric vehicle course. In addition Dr. Siavoshani is the Chief Industry Advisor for SAE Professional Development Department’s hybrid vehicle technology curriculum. Over the past two decades, he has worked for General Motors Corporation and Ford Motor Company. During his career, Dr. Siavoshani has worked on composite projects related to offshore oil and gas, infrastructures, and pressure vessels and automotive systems including vehicle powertrain, body, exterior/interior vehicle, and exhaust/induction systems. He has been instrumental in the development of new technology, notably the integrated Front of Dashboard concept and Acoustomize, a unique method of analyzing and offering solutions to automotive noise problems. He has also worked in the area of thermoforming utilizing electro-magnetic field technology. Dr. Siavoshani has helped to build the infrastructure for the electric vehicle battery pack including thermal management as well as reducing the weight of the overall battery. He has been granted several patents and was presented the Forest R. McFarland Award in 2012 for distinction in professional development and education. Dr. Siavoshani has a M.S. in Mechanical Engineering from Wayne State University and a Ph.D. in Mechanical Engineering from Oakland University.
Doug Adams
Dr. Adams is the Kenninger Professor of Mechanical Engineering at Purdue University and serves as Director of the Purdue Center for Systems Integrity, a facility dedicated to interdisciplinary research in the field of structural health monitoring and damage prognosis. His research has generated 13 U.S. provisional patents and 3 utility patents which are enabling the commercialization of these technologies by industry to increase the reliability and reduce the cost of aerospace, automotive and energy related equipment. Dr. Adams has published numerous archival journal and conference papers, written a comprehensive textbook and book chapters and has served as Associate Editor of ASME Journal of Dynamic Systems Measurement and Control and currently serves as Managing Editor of Structural Health Monitoring: An International Journal. He has delivered multiple short courses, invited presentations and keynote addresses for federal agencies and industry. Dr. Adams received the Presidential Early Career Award for Scientists and Engineers from President George W. Bush in 2002, was named a Fellow of ASME, and has received numerous teaching and research awards from the American Society of Mechanical Engineers, Society for Experimental Mechanics, and the U.S. Department of Defense. Dr. Adams received his degrees in mechanical engineering from the University of Cincinnati and MIT.
Pascal Hubert
Dr. Hubert is currently an Associate Professor at McGill University where he specializes in computational and experimental mechanics and processing for composite materials. Prior to joining the university, he was the owner of Composites Innovation Inc.,served as a Visiting Scientist as NASA Langley Research Center and worked in industry for Forintek Canada Corporation and Bombardier Inc. Dr. Hubert received his B.S in Mechanical Engineering and M.ScA in Composites Materials from the Universite de Montreal and his Ph.D in Composites Materials from the University of British Columbia.
Gary Lownsdale
Gary Lownsdale brings to the automotive industry over 46 years of research and development experience in polymers and composite materials. He began his career at Chrysler Corporation developing light weight solutions for muscle cars and then moved on to Ford Motor Company as Principal Design Engineer and introduced the first injection molded light truck instrument panels and light weight body structures on light truck vehicles. Later in his career he was with GE Plastics leading the introduction of development of injection molded exterior body panels with BMW on the Z-1 sports car and served as Honorary Chief Engineer of Exterior Body Panels at GM Saturn Corporation. Gary also served as President for MasterCraft Boat Company, President of Trans Tech International, and CEO for Aurora Lighting and as an industry consultant on nano materials and carbon fiber while working with Oak Ridge National Labs. He has been with Plasan Carbon Composites for over 4 years and serves as Chief Technology Officer overseeing the development of low cost light weight solutions to the mass production of carbon fiber products currently in use on the Dodge Viper and the Corvette models. He recently completed a patent for a fast production out-of-autoclave process solution for carbon fiber, which will be utilized to produce a 2014 model next year. Mr. Lownsdale is a graduate in Mechanical Engineering from the University of Cincinnati.
Pankaj K. Mallick
P. K. Mallick is the William E. Stirton Professor of Mechanical Engineering and the Director of the Interdisciplinary Engineering Programs at the University of Michigan-Dearborn. He is also the director of the Center for Lightweighting Automotive Materials and Processing at the university. Dr. Mallick worked in industry for several years before joining the university where his principal research areas are mechanical properties, design characteristics, joining and processing of polymers, fiber reinforced composites and lightweight automotive materials. He has authored or co-authored three books on fiber reinforced composites, including Fiber Reinforced Composites: Materials, Manufacturing and Design and Materials, Manufacturing and Design for Lightweight Vehicles. Dr. Mallick is the recipient of the Distinguished Faculty Research Award from the university and the Distinguished Faculty Award from the Michigan Association of Governing Board of State Universities and is a Fellow of the American Society of Mechanical Engineers. He received his Ph.D. from the Illinois Institute of Technology.
Anoush Poursartip
Dr. Poursartip has played an international leadership role in the advancement of composites processing science and technologies in academe and the aerospace industry and has received global recognition for his work on process design software. He is a Professor in the Department of Materials Engineering at The University of British Columbia in Vancouver, Canada. Working closely with two colleagues, he directs the Composites Group at UBC, an interdisciplinary research group from Materials Engineering and Civil Engineering, with facilities in the state-of-the-art Advanced Materials and Process Engineering Laboratory. Dr. Poursartip has been a long-standing member of the Executive Council of the International Committee on Composite Materials, including serving as Executive Secretary and President and has been a member of the editorial boards of the Journal of Composite Materials and Composites Part A. He is also a World Fellow and Life Member of ICCM and has won two Outstanding Performance Awards from The Boeing Company. Dr. Poursartip earned a B.A. and Ph.D. from Cambridge University in the United Kingdom.
Khaled Shahwan
Dr. Shahwan is a world recognized expert and an industry leader in state-of-the-art virtual methodologies and engineering for advanced lightweight composites and automotive safety technologies. He is a member of the Board of Directors of the Automotive Composites Consortium (ACC)—a division of the U.S. Council for Automotive Research (USCAR), where he served as Chairman of the Board in 2011. He has held several expanding roles within the ACC leadership including the Chairman of the Predictive Technology Development and Composites Crash Energy Management Group. Dr. Shahwan is a leading member of several industry-government collaborative programs (NASA, USAMP, MTT/USDRIVE), and has initiated and managed several long-term collaborative R&D and innovation projects between the OEMs, suppliers, leading academic institutions and U.S. Dept. of Energy. He currently works at the Chrysler Technology Center where he is a leading specialist in light-weighting and advanced computational methodologies as well as passive and active (crash avoidance) safety technologies. Prior to joining Chrysler, Dr. Shahwan worked for several years at Ford Research Labs and Ford’s Advanced Engineering. Earlier in his career he held senior consulting and research positions in industry and at the University of Michigan-Ann Arbor. Dr. Shahwan is a member of the Editorial Boards of the Journal of Engineering Mechanics, and the International Journal of Vehicle Safety. He is an elected Associate Fellow of the American Institute of Aeronautics and Astronautics (AIAA), has numerous peer-reviewed and corporate and industry-government collaboration reports and publications and has received several recognitions including the Special Recognition Award for Outstanding Contributions by USCAR, as well as the Executive & Team Leadership (Technology Innovation) Award by the Society of Plastics Engineers (SPE). Dr. Shahwan holds a Ph.D. and an M.S. in Aerospace Engineering, and an M.S. in Structural Engineering from the University of Michigan-Ann Arbor, and a B.S. in Civil Engineering from San Francisco State University.
Dave Warren
Dr. Warren is currently the Program Manager for the Transportation Materials Program at Oak Ridge National Laboratory (ORNL) and Field Technical Manager for Materials in the Lightweighting Materials sub-program of DOE Vehicle Technologies where his focus is on materials science technologies related to carbon fiber, carbon fiber composites, glass fiber composites, magnesium, aluminum, titanium, and high strength steels. Prior to joining ORNL, he served as Program Manager for Peacekeeper ICBM propulsion, Small ICBM basing and Rail Garrison support as a Captain in the United States Air Force. He has numerous technical publications focused mainly on composite materials development and application and has chaired international conferences and sessions and given plenary or keynote addresses. His membership on boards and steering committees includes: USDRIVE Materials Tech Team; U.S. Automotive Materials Partnership; Georgia Technological University – Materials Science Department Review Board; University of Alabama – Birmingham – GATE Materials Science Advisory Board. Dave completed undergraduate and graduate work in materials science and engineering at Vanderbilt University.
Xinran (Sharon) Xiao
Xinran (Sharon) Xiao is an Associate Professor of Mechanical Engineering at Michigan State University (MSU). Her research interest is on mechanical behavior of materials and modeling, including composite constitutive models for crashworthiness analysis. She is the current chair of the Analysis and Testing Division of the American Society for Composites (ASC). Before joining MSU in 2008, she worked as a Senior Engineer at General Motors Engineering Division (1999-2001) and a Staff Researcher at its R&D center (2002-2008). At GM, one of her primary responsibilities was to support materials models for crashworthiness analysis of composite structures. She had contributed to crash analysis for some composite structures that went into products. She won the General Motors Charles L. McCuen Award in 2007, Tech Center Award in 1999. She served as a co-Chair of the Composite Materials Handbook (CMH) 17, Crashworthiness Working Group, Federal Aviation Administration (FAA) (2006-2009), a member of the Energy Management Member, Automotive Composite Consortium (ACC) of United States Council for Automotive Research (USCAR) (2001-2008), a member of the SAE high strain rate tensile testing standardization committee (2000-2008). She was an Assistant and then Associate Professor at Concordia University, Montreal, Canada (1992-1999), a research associate at IMI of National Research Council Canada (1991) and at Concordia University (1988-1990). Xiao received a Ph.D. in Applied Sciences from Free University of Brussels (VUB) in 1987, a B.Eng. (1982) and M.S. (1985) in Materials Science and Engineering from Beijing University of Aeronautics and Astronautics (BUAA).
Pablo Zavattieri
Dr. Zavattieri is currently an Assistant Professor at Purdue University where his research interests are in the area of computational solid mechanics applied to the multi-scale analysis of advanced materials subjected to extreme conditions. His current research includes investigation of the mechanics of conventional composites materials, biomineralized organisms, biomimetic composites, nanocellulose-based composites, and multifunctional and smart materials. Prior to joining Purdue he served as a Senior Researcher and Staff Researcher at the General Motors Research and Development Center. Dr. Zavattieri serves as a technical reviewer, symposium organizer and editor for numerous organizations and publications. He received his bachelor’s and master’s degrees in Nuclear Engineering from the Balseiro Institute, Argentina and his Ph.D. from the School of Aeronautics and Astronautics at Purdue University.
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