Save the Date Wednesday, November 20 - Thursday, November 21, 2024 | Charleston, SC
MetalForming magazine and the Precision Metalforming Association are proud to deliver this one-of-a-kind event that provides a unique opportunity to dive deeply into the ever-expanding world of hot stamping. Gaining popularity among automotive OEMs and Tier suppliers, as well as other industries, hot stamping is becoming a go-to process for the production of lighter and safer vehicles.
In addition to the presentations, attendees will tour the Nucor Steel Berkeley mill in Huger, SC. Attendees will view the production of a variety of steel products, including structural steel and carbon-steel plate and sheet products. Featured: low-carbon EAF steelmaking via tours of the melt shop, caster and hot mill.
The event will take place at the Embassy Suites by Hilton Charleston Airport Hotel & Convention Center.
As the automotive sector moves further into electrification, the need to reduce cost and manufacturing complexity increases. As part of this initiative, part consolidation through use of extreme-size components is gaining traction.
Gestamp utilizes Extreme-Size Stamping Strategies to address higher impact energy levels. Benefits include part count reduction, reduced vehicle build time/complexity, green steel attributes and recyclability. Gestamp uses a holistic approach to vehicle energy management, addressing the impact event in stages with the body structure. Although all impact events are critical, the side impact and shallow offset rigid barrier are two that Gestamp has a great deal of experience with, providing many innovative solutions. Gestamp's focus today is how to best use steel door ring concepts to manage the IIHS 2.0 side impact and SORB events, while protecting the occupant and battery enclosure.
Gestamp's OLPB Door Ring and GES-Wire tailor welded blank innovations offer high strength low-cost solutions to the energy management challenge. The OLPB Door Ring, comprised of spot-welded blanks prior to hot stamping, offers (~7-10%) cost savings over traditional architectures while reducing mass, part count and plant complexity.
To further address cost savings, Gestamp is also introducing the 2nd Generation Multistep Hot Stamping manufacturing innovation. This new, revolutionary hot stamping process produces parts ~3-4x faster than conventional hot stamping, and achieves strength and ductility equal to, or better than the conventional AlSi 1500 MPa material.
Root-Cause Analysis of Hot Stamping Defects…and Best Practices for Prevention
This presentation will address how hot-stamped part defects compare to cold-stamped defects, how the unique challenges of the hot-stamping process are managed, and how the heat treatment process impacts part geometry and tolerances as well as secondary production operations. This session also will delve into determining the root cause of a hot-stamped defect and the best ways to control defects once root causes are identified and correlated to hot-stamping process variables.
New Production Strategies for PHS Parts Trimming Based on Five-Axis Cutting Systems
This trend combines previously separate components into larger, unified structures, yielding substantial benefits in cost efficiency, reduced complexity, and sustainable material utilization.
In this presentation, we will showcase the application of ring beam-shaping technology, enabling higher cutting speeds with reduced gas consumption. This advancement not only enhances operational efficiency but also aligns with sustainability goals through resource conservation.
Additional focus is on innovative production concepts with the integration of multiple five-axis systems, establishing high quality at full traceability. Finally, these processes prioritize user-friendliness, reducing operator learning curves, while also minimizing floor-space requirements, resulting in cost savings and optimized material logistics.
Hot Stamped Steel and Projection Welding – Is It Possible?
Hot-stamped steels usually have tensile strengths of 1500 MPa, making them desirable for many uses in the automotive industry but offering severe complications when trying to projection weld a component which is of considerable softer material. The softer projection tends to collapse before a good weld can be made, resulting in vaporized projections and failed welds.
It is possible to make successful projection welds on hot stamped steels, but it takes an understanding of the process that made the steel. This discussion will look into the different methods of hot forming steels and how they affect the projection resistance welding process. Different resistance welding methods also will be discussed how they affect, as well as how to properly test projection weldments.
Managing the Hot Stamping Process: Critical Features when Ordering a Line Press
Rick has worked in the stamping business for 35 years, six of those years building presses and 20 years project-managing press installations and building plants. He has a BSc in Mechanical Engineering and an MBA. Most recently, Rick spent 5 years as VP of Manufacturing Engineering at Cleveland Cliffs Tooling and Stamping, in charge of business development, maintenance and purchasing. While there he oversaw the construction of two factories and installation of six hot stamping lines, as well as some 20 laser cutting machines. As COO of Eagle Press & Equipment, Rick runs one of the few press-building facilities in North America.
The Compact Strip Production Process for PHS Grades
Nucor has a carbon intensity less than half of today’s world average total emissions. And now the steelmaker is committing to a 35% combined reduction in steel mill scope 1 and scope 2 GHG intensity by 2030. This talk focuses on Nucor’s production of PHS grades for the automotive industry using the Compact Strip Production (CSP) process, with a high recycled content and a low carbon footprint. And, the steelmaker now is developing 2-GPa PHS, as well as other types of PHS grades.
Following this talk, attendees will be briefed on tour of the Nucor Steel Berkeley mill, which also uses the CSP process.
Director - Mfg. Engineering, Diversified Tooling Group, Inc.
Mike Austin is Director of Manufacturing Engineering for Diversified Tooling Group, whose American Tooling Center operation supplies hot stamping dies to automotive OEMs and suppliers. Mike has headed up the hot stamping development activities team at DTG for the last 7 years including the installation of their AP&T Hot Forming Press Cell, Prima LaserNextfive-axis laser cutting cells, and hot stamping focused metallurgical lab. Mike has 47 years of industry experience in automated processes for hot forming and cold stamping, has authored a number of papers and is a frequent speaker on metalforming subjects.
Paul Belanger
Director, North American R&D Center, Gestamp R&D North America Inc
Paul Belanger leads a team of body engineers developing products and new technol...
Director, North American R&D Center, Gestamp R&D North America Inc
Paul Belanger leads a team of body engineers developing products and new technologies at Gestamp's North American R&D Center.
Paul started his career in the steel industry before moving into automotive with Chrysler's Materials Engineering and Ram Truck Body Engineering. Later, at GM, he led a manufacturing engineering team providing expertise with critical stampings and complex assemblies.
Paul has been using his more than 35 years of automotive body and materials engineering experience to drive the development and optimum application of advanced sheet metal products into automotive vehicle production.
Yama Fedai
Key Account Manager & Industry Manager, TRUMPF Inc.
Yama Fedai has been an Industry Manager for Automotive Structures and Automation...
Key Account Manager & Industry Manager, TRUMPF Inc.
Yama Fedai has been an Industry Manager for Automotive Structures and Automation at TRUMPF for the last 3 years. As an Industry Manager, he focuses on the evolution of the automotive manufacturing landscape, and how technology can address evolving industry needs. He has 18 years of manufacturing experience working in various growing roles, including automated assembly lines processing, design, build and launch. He was responsible for launches of major hot stamping programs including blanking, hot stamp/cold stamp dies, laser cutting and joining.
Dean Kanelos
Automotive Market Development & Product ..., Nucor Automotive Group
Dean Kanelos is the automotive market development and product applications manag...
Automotive Market Development & Product Applications Manager, Nucor Automotive Group
Dean Kanelos is the automotive market development and product applications manager at Nucor. He has been with Nucor for twenty two years, overseeing automotive market development, product applications, early vendor involvement and assisting in product development. Dean is chairman for WorldAutoSteel and chairman of the Auto/Steel Partnership's Joint Policy Council. He has 44 years of experience in the steel industry, having worked in production supervision, applications engineering, marketing, and market development. Dean has a Bachelor's degree in Metallurgical Engineering from the University of Wisconsin-Madison and a Master's in Business Administration from Indiana University-Northwest.
Ray Michelena
Safety Director/Seminar Instructor, T. J. Snow Company
Ray Michelena has more than 20 years of experience with resistance welding. As ...
Safety Director/Seminar Instructor, T. J. Snow Company
Ray Michelena has more than 20 years of experience with resistance welding. As one of T. J. Snow Company's resistance welding seminar instructors and service techs, he travels to metalworking plants nationwide. He also is the company's safety director and chief pilot.
Paul Thom
Sales Manager-Hydraulic Division, Schuler North America
Paul Thom has significant knowledge of lightweight and forming technologies with...
Sales Manager-Hydraulic Division, Schuler North America
Paul Thom has significant knowledge of lightweight and forming technologies with his Master of Science in Production Management, in cooperation with Daimler Trucks, and industrial engineering background. His career at Schuler began in 2013 as a Sales Manager of hydraulic presses, for which he was responsible for hot stamping lines worldwide. Paul's expertise in hydraulic and forging press systems expanded market opportunities at Schuler North America, US subsidiary of Schuler Group, during his tenure overseas. Paul currently continues his work at Schuler Pressen GmbH in Gemmingen, Germany, where he resides with his wife and two young children.
Rick Uszynski
COO, Eagle Press & Equipment Co. Ltd.
Rick has worked in the stamping business for 35 years, six of those years spent ...
Rick has worked in the stamping business for 35 years, six of those years spent building presses and 20 years project-managing press installations and building new plants. He has a BSc in Mechanical Engineering and an MBA. Most recently, RIck spent 5 years as VP of Manufacturing Engineering at Cleveland Cliffs Tooling and Stamping, where he was in charge of business development, maintenance and purchasing. While there, he oversaw the building of two factories and installation of six hot stamp lines, as well as some 20 laser cutting machines. As COO of Eagle Press & Equipment, Rick runs one of the few press-building facilities in North America.
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