Materials and Lightweighting Technical Sessions - Program - WCX™ World Congress Experience

Materials and Lightweighting Technical Sessions

Session Titles

Session Descriptions

Advances in Lightweight Materials

This session presents the latest developments in automotive applications of wrought products. The papers cover a wide range of the technical aspects including alloy development, lightweight design, multi-material usage for body structures, process development and simulation as well as performance optimization.

Applications of Advanced High-Strength Steels and Press Hardening for Automotive Structures

This symposium provides a forum for researchers and application engineers to disseminate the knowledge and information gained in the area of advanced high-strength and press-hardening steel development and applications in automotive structures, enabling light-weight and durable vehicles with improved safety.

Sheet Metal Forming Technology

This session will feature the latest developments in sheet metal forming technology. Presentations will address general areas of forming processes, formability issues and modeling. These include forming processes (Stamping, hydroforming, gas forming, high temperature forming), formability Issues (springback, edge cracking, stretch-bend failures and fracture), Modeling (materials, forming limits, failure criteria in various deformation modes and process modeling & optimization).

Advances in Metalcasting

Metalcasting is one of the oldest manufacturing processes, dating back over five millennia.  However, recent advances continue to expand the horizons of metalcasting: new alloys and new casting techniques are leading to enhanced properties, process modeling and simulation tools are enabling better casting designs, the increasing use of metal-matrix composites is opening new frontiers in casting performance, and additive manufacturing techniques such as 3D printing of pattern materials are reducing lead times for prototype castings.  This session will cover the latest developments in ferrous and non-ferrous metalcasting technologies for the mobility industry.

Failure Analysis of Materials, Components, and Systems

The mobility industry is constantly challenged to provide customers with the ultimate in reliability and durability.  As a result, when failures occur during testing or real-world service, it is essential to identify the root cause and take appropriate corrective action in a timely manner.  This session will cover failure analysis methodology, fundamentals of failure mechanisms, non-destructive evaluation, fractography, material fatigue testing, fatigue life design for vehicles, material fracture criteria, damage and fracture characterization, fracture prediction in vehicle crash, material fracture behavior in high strain rates, etc., and creative problem-solving case examples of failure analysis and prevention.

Fatigue Analysis & Design

This session focuses on innovative and improved fatigue analysis/design methodologies and problem solving techniques in the ground vehicle industry. The subjects of interest include studies and discussion on (1) structural stress generation, (2) fatigue of metallic material including new lightweight metals, (3) fatigue of non-metallic materials (plastic, elastomer and composites), (4) fatigue of joints and bearings (mechanical, welded, and adhesive-bonding), (5) environmental effects on fatigue performance (elevated temperatures, oxidation, corrosion, and humidity), (6) effect of manufacturing processes on fatigue behavior (surface treatment, residual stresses), (7) vibration fatigue, (8) probabilistic fatigue, and (9) microstructure-mechanics based fatigue.

Advanced Analysis, Design, and Optimization of Materials, Restraints, and Structures for Enhanced Automotive Safety and Weight Reduction

This session explores innovative ideas to enhance automotive safety with improved material constitutive modeling, analysis method developments, simulation and pre/post processing tools, optimization techniques, crash code developments, finite element model updating, model validation and verification techniques, dummies and occupants, restraint systems, passive safety as well as lightweight material applications and designs.

Automotive Engineering Testing and Test Methods 

The focus of this session are the tests and test methods employed in the evaluation of the performance and durability of powertrain (engines, transmissions), driveline (4WD systems, driveshafts, axles), chassis (frame, suspensions, brakes, etc.)  and body components, subsystems, and full vehicle systems.

Optical Measurement and Nondestructive Testing Techniques in Automotive Engineering

Optical based Techniques/technologies for Materials Characterization, Strain/Measurement, Nondestructive Testing, and Validation of Materials Models etc.

Materials Characterization and Modeling

Materials are very important for vehicle design and performance. From the traditional combustion engines to electrified powertrain systems and battery, material challenges occur in almost every design step. This session focuses on material characterization and modeling technique already or potentially involved in automobile industry. Special emphases are residual stress, microstructure and properties during additive manufacturing, crack growth and interaction with environment, battery materials and simulation.

Key words:  residual stress, microstructure, mechanical properties, additive manufacturing, crack growth, environment effects, battery materials, material modeling, simulation

Load Simulation and Vehicle Performance: Nonlinear Components/Systems

Focusing on new theory, formulation and modeling of amplitude-, frequency- and temperature-dependent nonlinear components/systems such as mounts or bushings, shock absorbers, and joint friction/damping; dynamic characterization through lab and field testing; Linearization methodology; Model validation, application, and sensitivity analysis in vehicle system/subsystem simulations; Nonlinear system identification, modeling, and application in testing accuracy improvement, etc.

Load Simulation and Vehicle Performance: Ride Comfort

Focusing on vehicle ride comfort, addressing issues such as ride evaluation, suspension tuning, occupant biomechanics, seating dynamics, and semi-active and active suspensions. Topics may include traditional vehicle primary and secondary ride issues, structural shake, brake pulsation, smooth road shake, power hop, launch shudder, freeway hop, etc. and any new ride issues raised from electric vehicles (e.g. in-wheel motors driven EVs) and autonomous vehicles (e.g. motion sickness prevention through vehicle design and driving pattern optimization).

Load Simulation and Vehicle Performance: Tire and Terrain 

Focusing on tire and terrain mechanics modeling, tire model and test development, parameters identification, sensitivity analysis, road profile characterization, interactions between tire, suspension/steering/brake systems, and different terrains, spindle loads/travel variation attributes due to deterministic and rough roads, tire noise, rolling resistance, correlation studies, design of intelligent tires and ADAS, and changes in tire load duty cycles from traditional to autonomous vehicles.

Load Simulation and Vehicle Performance: Multi-body Dynamics and Intelligent Vehicle Dynamics

Multibody system modeling and simulation, rigid and flexible body modeling, loads predictions for vehicle body, frame/sub-frame, exhaust system, driveline, and powertrain, modeling of vehicle dynamics simulation and durability loads simulation, process considering vehicle dynamics and durability loads, data processing and analysis, loads sensitivity analyses for model parameters, design load minimization, prediction of loads effects, robust design methods, driver modeling, and system modeling.

Load Simulation and Vehicle Performance: Handling and Dynamics

Focusing on analysis and enhancement of vehicle dynamics performance including handling/braking/traction characteristics as well as robustness and active stability under the influence of loading, tire forces, and intelligent tire technology for improving overall vehicle system dynamics and safety. Influence of load variations and other uncertainties, as well as impact of system hybridization, electrification, and autonomous systems on vehicle dynamics and controls will be discussed.

NVH CAE Analysis & Testing Correlations

This session covers the forefront NVH development in electrical vehicle, ICE vehicle and autonomous vehicle - numerical methods along with test correlation and optimization for NVH issues of full vehicle and vehicle subsystems. All structural components, subsystems and complete systems found in automotive vehicles will be considered. Topics include noise control materials, structure NVH, vibro-acoustics, wind noise and aeroacoustics, intake/exhaust  noise and vehicle interior noise, sound quality etc.

Multi-Discipline Interaction and Special CAE Applications

This session will address recent advances in simulation technologies at scales ranging from theoretical development, real world CAE applications, and special simulation techniques for the hybrid, EV, fuel cell and autonomous vehicles. The session focus on the use of the combination of the dynamic, static, linear and nonlinear finite element (FE), mesh free, computational fluid dynamics (CFD), and multibody dynamics (MBD) to evaluate the performance of the vehicle system. Subject coverage topics include: mesh free, geometry-based methods and their applications; Fluid & Structure Coupling; Thermal & Structural Coupling; Electromagnetic and Structural Coupling; 1-D & 3-D Multi-Domain Coupling; Preload/Stress & Manufacture Effect Consideration in Simulations.

Automotive Tribology

This technical session focuses on fundamental and applied research that lowers frictional energy losses and enhances reliability and durability of automotive components. The topics include, but not limited to engine and drivetrain tribology, seals, bearing and gear lubrication, materials tribology, surface engineering, lubricants and additives, computer-aided tribology, tribotesting, as well as friction, wear and lubrication fundamentals.

Modeling and Simulation in Composites, Plastics, and Polymers

This session focuses on state-of-art developments in physical testing and modeling of plastics and fiber reinforced polymer composite materials for the automotive industry. Special emphasis will be given to material properties and microstructure modeling during manufacturing processes and material behavior under different environmental and loading conditions. Studies and discussions on innovative theories and experimental methods, constitutive behavior, integrated computational materials engineering (ICME), and CAE correlation with testing will also be addressed. Other materials considered for this session include rubbers, adhesives, metal/plastic hybrid and materials fabricated by additive manufacturing (3D printing).

Welding, Joining, and Fastening

Presentations related to welding and joining of similar or dissimilar materials of plastics, composites, aluminum, magnesium, titanium, and conventional and advanced high strength steels will be given.  Papers related to friction stir (spot) welding, ultrasonic welding, resistance welding, arc welding, laser welding, brazing or soldering, riveting and bolting, and adhesive are planned as well.   Papers related to strength, fracture and fatigue of welds, joints and fasteners have been invited.

Materials-Environment Interactions

Corrosion, oxidation, erosion, corrosion-fatigue, stress-corrosion cracking, wear, etc. These issues in aluminum and magnesium are immediate challenges to the development of lightweight materials. Modeling, simulation, testing, diagnosis, and mitigation related to these issues are all challenging and fascinating.

Automotive Polymeric, Plastic Components and Composites

Presentations of this session will address the development of polymeric and composite materials for automotive interiors and exteriors, powertrain components, as well as structural and non-structural applications. Focus is on design, processes, bonding and manufacturing technologies, as well as lightweighting strategies.

Advances in Instrument Panels, Seats, and Interiors

This session will feature technical presentations that will discuss new technology and industry insights in automotive interiors.  Focus areas include materials, perceived quality, environmental concerns, manufacturing, safety, and durability.

Automotive Composite Materials and Structures      

This section will provide a forum for engineers and researchers to share the latest developments on the design, manufacturing, characterization, and application of automotive composite materials and structures for next-generation vehicles.  Specific topics of interest include, but are not limited to: new paradigms of design and development of composite materials; new manufacturing processes of composite materials; novel experiments for characterization of composite materials and structures; damage, failure, and fatigue testing of composites; responses of composites subjected to extreme environments or loading conditions; practical designs of composite structures for all aspects of automotive applications.

Advances in Coatings

Presentations of this session will address application and research on coatings for exterior body and plastics (including polycarbonate) as well as vehicle interiors and underbody/underhood.  Focus will be on the 3-10 year timeframe.

UV EB Materials for 3D printing and Automotive Applications

Success in cure technology attained through advances photocurable materials, UV Laser technology, lamp development, 3D computer imaging, and the development of novel materials, processes and facilities, are significantly advancing the efforts of energy reduction and vehicle lightweighting resulting in improvements of reduced GHG emissions, manufacturing Cycle Time, Small Footprint manufacturing, speedy proto-type development and Additive Manufacturing, all creating a revolution in manufacturing.

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