Wednesday, August 30

8:00 a.m. Registration and Continental Breakfast
8:30 a.m. Welcome remarks
8:45 a.m. New Advancements in Aluminum Sheet Technology
for Design and Manufacturing
John (J.P.) McGuire, Sr. Manager, R&D and Applications Engineering, Aleris International, North American Innovation Center, Madison Heights, MI
New trends in lightweighting have driven the greater use of aluminum for closures and automotive structures. Even greater penetration of aluminum is predicted in the future. With this change from steel-intensive to aluminum-intensive design, a systems approach is recommended to optimize the product, materials and stamping process uniquely for aluminum, due to its different behavior compared to steel.

This presentation focuses on the latest improvements in stamping design, aluminum materials, and simulation techniques to help ensure success when stamping aluminum and building subassemblies.

9:30 a.m. Aluminum Alloy Properties and Selection Criteria
Scott Warford, National Sales Director, Almetals
10:15 a.m. Resistance Welding of Aluminum
Ray Michelena and Jeff Morgan, TJ Snow Co.
10:30 a.m. Break
11:15 a.m. Arc Welding of Aluminum
Frank Armao, Director of Aluminum Technology, The Lincoln Electric Co.
12:00 p.m. Sensing Challenges When Stamping and Welding Nonferrous Materials (Like Aluminum): Electronic Tricks of the Trade
Dave Bird, Key Account Manager, and Shawn Day, Product Marketing Manager, Balluff Inc.
Stamping ferrous materials presents its own set of challenges, and post-forming assembly operations such as welding follow suit. Reliable detection, electronic measurement and specific RFID track-and-trace systems used in forming and welding of aluminum, aluminum alloys and exotic metals presents their own set of properties and related challenges. In this session, we will share with attendees some real-world applications that our field personnel have encountered with these materials, and describe successful sensing, electronic measurement, RFID and network/connectivity solutions.
1:15 p.m. Lunch
Transitioning from Steel to Aluminum:
Challenges Facing the Automotive Industry
Daniel J. Schaeffler, President, Engineering Quality Solutions, Inc. and Chief Content Officer, 4M Partners, LLC
There is no bigger user of sheetmetal than the automotive industry. For decades, their stamping and assembly infrastructure centered around steel-intensive vehicles. Increasing fuel economy and emission regulations are driving global automotive companies to transition some of their sheetmetal stampings from steel to aluminum alloys. This talk will help attendees understand the forming and joining challenges critical to aid in a smooth transition.
2:00 p.m. Straightening and Feeding Aluminum
Tom Brockie and Bruce Grant, Coe Press Equipment
Experts predict that aluminum sheet for light-vehicle body and closure parts will grow from what was less than 200 million lb. in 2012 to nearly 4 billion lb. by 2025. The benefits of aluminum are well documented, but given its large grain microstructure, aluminum acts significantly different than steel and requires special consideration in the pressroom. For example, the aluminum surface is softer and more sensitive to scratches, dents, etc. And, although aluminum's low yield and tensile strength might appear to make it easier to straighten, its lower elastic modulus makes aluminum conducive to springback.

This presentation will highlight specific design features of feeders and straighteners that metalformers should consider for aluminum applications. Recommendations will be made regarding roll materials throughout the coil-processing system, as well as roll spacing, optimizing feed profiles, counterbalancing options, controls consideration and more. Real-life applications will be discussed including equipment retrofits that can be performed to accommodate aluminum.
3:15 p.m. Lubrinomics for Aluminum Metalforming
Steve Lowery, Vice President and Director of Sales, Tower Oil & Technology Co.
Metalforming processes and procedures are being challenged by the increased use of aluminum alloys. Many facets of the tool build and overall manufacturing process often must be changed to deal with these new alloys, including lubrication. Here we will review numerous lubrication-related topics to ensure aluminum compatibility and optimum performance, including:
  • Choosing the right lubricant composition for aluminum alloys
  • Compatibility of lubricants
  • Post-processing of alternative lubrication
  • Environmental impact of stamping lubrication
4:00 p.m. Adjourn