SAE Professional Development Resource Guide 2013 - 111

Materials
Automotive Composites Technology Engineering Academy
5 Days I.D.# ACAD08

111

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 LFTProcessing 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 • Crash modeling • Adhesive joints modeling • Code discussions: LS-Dyna (MAT-54, MAT-58, MAT162), ABAQUS Explicit (VUMAT), ALTAIR RADIOSS, ESI PAM-CRASHComposite 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

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.

Catalog Key

Instructor-led programs

Online courses

ACTAR approved

Part of a Certiﬁcate Program Curriculum
SAE Professional Development Resource Guide 2013

Table of Contents for the Digital Edition of SAE Professional Development Resource Guide 2013
