AMF BOOKLET

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Lightweight Materials and Technologies: Lightweight Materials and Technologies: Trends, Applications and Trends, Applications and Opportunities for Manufacturing Opportunities for Manufacturing 13 July 2016, Wednesday | 8.30am - 4.30pm Grand Copthorne Waterfront Hotel Singapore Organised by: Partners: In Collaboration with:

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing The Annual Manufacturing Forum 2016 (AMF’ 16), in its 11th edition, features Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing. Industry key players and technology leaders will share state-of-the-art and future lightweight technologies in their respective domains and how these can be captured into creating value for various industries. Lightweight materials can be applied in many sectors and are increasingly important to transportation manufacturing sectors, including automotive, aerospace and even the defence industry. The construction, oil and gas and consumer goods sectors are also increasingly replacing conventional materials with lightweight ones. This presents new opportunities for our local SMEs to harness the potential of lightweight materials in the different industry clusters.

PROGRAMME Annual Manufacturing Forum 2016 Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing 13 July 2016, Wednesday | 8.30am - 4.30pm | Grand Copthorne Waterfront Hotel Singapore 9.00am Welcome Address Mr Steven Tong Chairman of AMF’16 Organising Committee Singapore Institute of Manufacturing Technology 9.05am Annual Manufacturing Lecture I (Transport): Opportunities for Advanced Materials Manufacturing to Reduce Weight in Transportation Applications Professor Alan Taub Chief Technology Officer Lightweight Innovations for Tomorrow (LIFT) 9.55am Annual Manufacturing Lecture II: The Status and Technical Issues Surrounding Composite Materials in the Aeronautics Industry Mr Koichi Nakamura Manager, Manufacturing Technology Research Department Research & Innovation Centre, Mitsubishi Heavy Industries Ltd 10.45am Coffee Break and Exhibition Tour 11.15am Keynote I: Materials and Lightweight Design Development Mr Johan Lindqvist Programme Manager Volvo Group 11.50am Keynote II: Challenges and Opportunities of Lightweighting in Cabin Interiors Mr Lau Hwa Peng Senior Vice President of Engineering Singapore Airlines 12.25pm Keynote III: Global Outlook of Light Weighting Trends and their Implications Ms Krithika Tyagarajan Vice President, Chemicals and Materials Practice Frost & Sullivan 1.00pm Networking Lunch and Exhibition Tour

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Parallel Track I: Polymer & Composites Parallel Track II: Light Metal & Alloys Chairperson: Dr Feih Stefanie Chairperson: Dr Chua Beng Wah 2.00pm Key Technology Lecture: Lightweight Key Technology Lecture: Understanding the Composites: Fundamentals, Challenges and Fatigue Response of Lightweight Metallic Alloys Perspectives Professor Alexander Korsunsky Professor Ignaas Verpoest Department of Engineering Science Department of Materials Engineering University of Oxford Katholieke Universiteit Leuven 2.30pm The Challenge to Building a Green Product - 3D Roll Forming of Sheet Metal - A New Method Lightweight and Recyclable Aircraft Seat to Make Load Optimised Profiles with Variable Dr Zheng Guo Ying Cross Sections Director, Engineering Mr Albert Sedlmaier ST Aerospace Ltd Managing Director data M Sheet Metal Solutions 2.50pm Creating Structural Products with Green Unlocking the Potential of Additive Materials Manufacturing for Lightweight Design Mr Joris Nooten Dr Robert Yancey Business Development Director Vice President - Additive Manufacturing Eco-Space (S) Pte Ltd Altair Engineering 3.10pm Coffee Break and Networking 3.30pm Foam Extrusion of Fine and Microcellular Lightweight Design Optimisation of Steel Thermoplastic Materials Structures for Marine and Offshore Vessel Mr Sebastian Schraube Application Process Engineer, Foam Technology Mr Esko Karvonen Leistritz SEA Pte Ltd Vice President, Offshore Deck Machinery Division MacGregor Pte Ltd, Singapore 3.50pm Dassault Systèmes Additive Manufacturing Rotary and Linear Friction Welding of Strategy Lightweight Materials Dr Mike Sheh Mr Alexander Wick Senior Director General Manager SIMULIA Asia Pacific KUKA Industries 4.10pm Science-based Generative and Functional Carpenter Technology Advanced Material Design and Global Production System for Mr Jose Carranza Vega Additive Manufacturing Regional Metallurgist, Asia Pacific Mr Olivier Hardy Carpenter Technology Asia Pacific Pte Ltd Global Account Aerospace & Defense Expert Sales Manager Dassault Systèmes 4.30pm End * Programme is subject to change without prior notice

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Annual Manufacturing Lecture I (Transport): Opportunities for Advanced Materials Manufacturing to Reduce Weight in Transportation Applications Professor Alan Taub Chief Technology Officer Lightweight Innovations for Tomorrow (LIFT) Professor, Materials Science & Engineering and Mechanical Engineering University of Michigan Abstract New solutions are needed to reduce the weight of the machines that move people and goods on land, sea and air. The current challenge is delivering the weight reduction economically. Meeting this goal requires optimising material properties and developing robust, high volume, manufacturing technologies and associated supply chains to fabricate components and subsystems at the appropriate costs. It is also important to develop robust design tools and joining technologies in which these optimal materials are used. Lightweight Innovations for Tomorrow (LIFT) was established to accelerate the adoption of advanced metallic structural components. It bridges basic research and final product commercialisation. Biography Alan Taub is the Chief Technical Officer of American Lightweight Materials Manufacturing Innovation Institute (ALMMII), Detroit, MI and a professor of Materials Science and Engineering at the University of Michigan. He also serves on the boards of several start-ups, including Nine Sigma, CellEra and Brightway Vision, and acts as a technical advisor for a new strategic venture fund, Auto Tech Ventures. Alan is a retired Vice President in General Motors’ Global Research Development Centre. Prior to his career in General Motors, Alan spent 15 years in research and development at General Electric, where he earned 26 patents and authored more than 60 papers. He also worked at Ford Motor Company for eight years. Alan is currently the Chair for the Visiting Committee on Advanced Technology (VCAT) for the National Institute of Standards and Technology (NIST) and a member of The Minerals, Metals & Materials Society (TMS) Energy Materials Blue Ribbon Panel. He also serves on advisory boards for the Massachusetts Institute of Technology, Northwestern University, and the University of California Davis and Berkeley. Alan was elected to the National Academy of Engineering in 2006. He received the Materials Research Society’s Special Recognition Award in 2004 and Woody White Service Award in 2002. He also received the Brown University Engineering Alumni Medal in 2002.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Annual Manufacturing Lecture II: The Status and Technical Issues Surrounding Composite Materials in the Aeronautics Industry Mr Koichi Nakamura Manager, Manufacturing Technology Research Department Research & Innovation Centre Mitsubishi Heavy Industries Ltd Abstract Ways to increase fuel efficiency and reduce maintenance costs are highly sought-after to lower the operating costs of commercial airplanes. This presentation introduces the past efforts, challenges, and expectations of reducing commercial planes’ operating costs from the perspective of material used for airframe structure. The lecture will touch on a developed composite material that can be used in the building of airframe structures. The developed material’s advantages and its area of applications will also be mentioned during the lecture. Biography Koichi Nakamura is a Manager of Manufacturing Technology No.2 Laboratory, Manufacturing Technology Research Department, Research and Innovation Center of Mitsubishi Heavy Industries, Ltd. He was appointed the position in April 2015 to lead a team in material development, process technology of fabrication and assembly using metals, chemical materials, and composite materials. He has 20 years of experience in design engineering, material and process technology development and automated assembly technology development, particularly in aerospace industries. Previously, Koichi led material and process (M&P) Engineering team and Electro-Magnetic-Effects (EME) engineering team of 787 main wings from 2003 to 2015. From 2003-2006, he joined the Boeing 787 Life Cycle Product Team in Everett, USA. Before joining Boeing Commercial Airplanes, he held several leadership roles within Bombardier commercial airplanes. From 1994 to 2002, he served in various technology and configuration development positions in Bombardier Global Express, DASH8-400, CRJ- 700/-900, and CL300. He attained his Master’s degree in metallurgy from the Kyushu University and joined Mitsubishi Heavy Industries, Ltd in 1993.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Keynote I: Materials and Lightweight Design Development Mr Johan Lindqvist Programme Manager Volvo Group Abstract A truck is a vehicle designed primarily to carry cargo. The payload (revenue generating cargo) is an important feature for the end-customer. If the payload can be increased, more cargo can be transported. This increases the end-customer revenue, reduces the number of required journeys and lowers CO2 emissions. Lightweight technologies are paramount to increasing payload. Weight legal requirements (for example, maximum allowed load per wheel axle) in different parts of the world allow an increase in payload if the weight of the truck is lowered. This means that a slight reduction in truck weight can increase payload by over 20 times, thus increasing the end-customer’s revenue substantially over the vehicle’s lifetime. The session will feature a summary of materials and production techniques in today’s manufacturing of trucks. An outlook on future Volvo group trucks products and its connected challenges will also be shared during the session. Biography Johan Lindqvist is a Programme Manager of Light Weight & Load Capacity Development, Volvo Group, Sweden. He joined the Volvo Group, one of the world’s leading manufacturers of trucks, buses, construction equipment, and drive systems for marine and industrial applications in 2005. At Volvo, Johan held various positions within heavy duty diesel engine development and the Materials Laboratory. He was appointed Programme Manager for Light Weight & Load Capacity Development in 2013. As a Programme Manager, he is in charge of setting strategies and driving all advanced engineering projects related to light weight and load capacity improvements. Materials, optimisations and advanced joining are the common themes running through Johan’s career. Johan graduated from the Royal Institute of Technology in Sweden 2001 with a major in solid mechanics and an EWE/IWE-diploma in welding. Upon graduation, he joined the Autoliv Group, the world’s largest automotive safety supplier introducing high strength steel in pressure vessels for airbag inflators and FEA/ thermodynamic simulations.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Keynote II: Challenges and Opportunities of Lightweighting in Cabin Interiors Mr Lau Hwa Peng Senior Vice President of Engineering Singapore Airlines Abstract The constant pressure for greater fuel efficiency and lower operating costs for airlines has gravitated the entire aerospace industry towards applying lightweight materials in new areas. Currently, lightweight materials are not only used in building aircraft. It is also used in building aircraft’s cabin interiors in which innovative materials and solutions are highly sought-after to meet the increasingly high demands of passengers in terms of cabin comfort and experience. This presentation touches on the challenges and opportunities of lightweighting in cabin interiors. Biography Lau Hwa Peng joined Singapore Airlines in 1992 as a Technical Services Engineer. He held positions in Production Planning, Engineering Planning, Engineering Supplies and Technical Projects before being appointed Manager Projects in 2000 and subsequently Senior Manager Technical Services in 2001. He was promoted to Vice-President Technical Services in 2004 and became Vice-President Company Planning & Fuel in 2009. He was then seconded to SIA Engineering Company as Vice-President Line Maintenance (Services & Projects) and Vice-President Heavy Maintenance & Planning in 2011. Hwa Peng returned to Head Office as Vice-President Technical Services in 2012. Hwa Peng was promoted to Divisional Vice-President Engineering (Fleet & Technical Services) in 2013. He took up the position of Divisional Vice-President Engineering (Technical Projects & Divisional Services) in 2014 and was appointed as Acting Senior Vice President Engineering in June 2015. Hwa Peng currently sits on the Board of Directors of Singapore Airlines Cargo and Singapore Aero Engine Services Private Limited (SAESL, a Rolls-Royce, Hong Kong Aero Engine Services Limited & SIA Engineering Company Joint Venture Company). He holds a Master of Business Administration from Nanyang Technological University and a Bachelor of Engineering (Mechanical) from the National University of Singapore.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Keynote III: Global Outlook of Light Weighting Trends and their Implications Ms Krithika Tyagarajan Vice President (Chemicals and Materials Practice) Frost & Sullivan Abstract Light weighting in vehicles is one of the key measures to reduce the weight of the vehicle. This improves fuel efficiency and helps OEMs accommodate to stringent CO2 emission regulations. The key focus areas for light weighting are related to body materials and powertrain. Industry-wide trend shows methods to reduce nearly one-fourth of a vehicle weight by using alternative materials such as Aluminium, Magnesium, Carbon Fibre Reinforced Plastics (CFRP), along with opportunities to reduce costs. Leading up to 2020 and starting with Body In White, Aluminium is expected to replace steel in the short-term (especially in premium segments) while CFRP will supplement Aluminium in the long-term. Biography Krithika Tyagarajan is the Vice President of the Chemicals and Materials Practice at Frost & Sullivan. She has over 15 years of experience in market research and consulting. At Frost & Sullivan, Krithika is involved in mentoring and developing teams with high standards on project management and quality delivery. She has provided strategic insights on several global consulting projects in the chemical industry. Her experience spans across industry-specific B2B research, market sizing, forecasting, competitor intelligence, customer satisfaction, distribution, project management, B2C research, quantitative and qualitative research and strategy research. She has also presented at various conferences around the region.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Parallel Track I: Polymer & Composites Key Technology Lecture: Lightweight Composites: Fundamentals, Challenges and Perspectives Professor Ignaas Verpoest Department of Materials Engineering Katholieke Universiteit Leuven Abstract Fibre-reinforced polymer matrix composites are lightweight materials with exceptional properties. They combine a high strength and level of stiffness, and has a density of about 50% - 75% aluminium and 20% steel. They are also durable in terms of fatigue and environmental properties. Manufacturing methods can be adapted to large series which require high production speeds, as well as to very large structures. For all these reasons, polymer composites have been realising a breakthrough in aerospace, automotive, sports and a diversity of industrial applications. However, these composites face challenges when further developed to go into more diverse markets. These challenges include developing cheaper carbon fibres (both monetary and ‘ecological cost’), increasing the efficiency of its production methods via automation as well as optimising its design processes. Further improvements in the ecological impact of composites can be achieved by using both natural fibres and bio-based polymers. All these aspects will be briefly introduced and examples of recent developments in these domains in Europe will be shared during this session. Biography Ignaas Verpoest received his master’s degree and his PhD in Materials Engineering at the Katholieke Universiteit (KU) Leuven (Belgium). As a full professor from 1990 till 2013, he guided 8 postdoctoral researchers and 25 PhD students to research on mesomechanics of textile-based composites, nano- engineered composites, natural fibre-reinforced bio-polymers and advanced production methods for composites. He published 330 journal papers, approximately 500 conference papers and 3 books and owns 15 patents. Since 2013, Ignaas is conferred as an emeritus professor and acts as the emeritus chairholder of the Toray Chair in Composite Materials at KU Leuven, and chairman of the European Scientific Committee of CELC, the European Confederation on Flax and Hemp. He was President of the European Society for Composite Materials, and the International Committee on Composite Materials. He was also the chairman of the Materials Research Centre at KU Leuven, and is currently a member of the Royal Flemish Academy of Belgium for Science and Art. Ignaas received several awards including the Descartes Prize for Science Communication of the European Commission (2004), the International Fellowship of the Society for the Advancement of Materials Processing (2009), and Engineering and the International Committee on Composite Materials (2009). He is also a co-founder and board member of the company Econcore, worldwide producer of innovative honeycomb cores.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Parallel Track I: Polymer & Composites The Challenge to Building a Green Product - Lightweight and Recyclable Aircraft Seat Dr Zheng Guo Ying Director, Engineering ST Aerospace Ltd Abstract In commercial airlines operations, weight reduction directly translates to saving energy. Recyclable products also lead to saving energy through waste reduction. At the same time, materials and processes are the key elements in creating high strength to weight ratio product, increasing structural efficiency and reducing weight. Nowadays, aircraft are increasingly being built with composite structures. Thermal plastic is also becoming more promising in creating lightweight and recyclable products. These thermal plastic parts have been produced via a moulding process in countries like Germany and Japan but this process is yet to be implemented here in Singapore. Located in Singapore, ST Aerospace Aircraft Seat Company is facing challenges of tapping into the advanced material, manufacturing technologies and processes to create a green product locally. These challenges will be discussed during the session for material suppliers and manufacturers to come together and create collaborative solutions. Biography Zheng Guoying is an Engineering Specialist in Structure and Interiors in ST Aerospace. Since joining ST Aerospace in 1999, she has served in various roles including Chief of Officer of Airworthiness of EASA DOA 21J292, Design Signatory of CAAS AW 023 and Compliance Verification Engineer. She is a pioneer in ST Aerospace’s Aircraft Seat Unit where she is currently the Director of Engineering. Her vast professional and academic experiences include designing civil structures, engineering and certification of various aircraft structures including interiors and seats of various materials, lecturing postgraduates and undergraduates, and performing research in dynamics and composite structures. She has also published a number of research papers and patents. Guoying is also active in promoting engineering, where she is a Fellow of IES; Member of CoF IES; Chartered Engineer of IES Aerospace Chapter; Committee Member of Aero Chapter IES; Member of IStructE (UK); Chartered Engineer (UK) and Member of WISE.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Parallel Track I: Polymer & Composites Creating Structural Products with Green Materials Mr Joris Nooten Business Development Director Eco-Space (S) Pte Ltd Abstract Green materials are becoming increasingly important. However, not many companies are tapping on the full potential of green materials. As most people are not familiar with green materials’ basic properties and the interesting aspects of materials made from CO2 neutral and renewable resources, green materials are used mainly for low-tech disposables and packaging. But there is more potential for these materials. This session will give the audience a hands-on experience of green material products that meet different and more demanding requirements, helping to broaden the horizon and adaptation of green materials. The session will also give designers new insights for potential applications of green materials. Biography Joris Nooten is a driven business developer with a solid network. With a technical education in chemistry and process technology from Eindhoven, The Netherlands, and over 15 years of experience in the world of rubber and thermoplastics, Joris has extensive knowledge of production processes and materials. Joris uses his experience as a starting point for the business development, where he applies his theoretical and applied knowledge to help clients adapt new technology and materials into their products and services. As an expert in Liquid Silicon Rubber (LSR), Joris’ practical approach has helped many companies adopt this technology. As Joris is familiar with product design and marketing, he has translated designs into parts that are feasible, assisting engineers to avoid pitfalls. Joris has been in a senior management position for over 10 years and has assisted in corporate efficiency programmes and relocations. He is convinced that there are green and economically sound solutions for linear supply chain operations and is dedicating his daily energy to bring these to the world.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Parallel Track I: Polymer & Composites Foam Extrusion of Fine and Microcellular Thermoplastic Materials Mr Sebastian Schraube Process Engineer, Foam Technology Leistritz SEA Pte Ltd Abstract Thermoplastic foams have diverse applications in our everyday lives. This is attributed to its numerous advantages such as light weight, excellent strength/weight ratios, insulating abilities, energy absorbing performance and comfort features. This session examines the applications of extruded thermoplastic foams and explains the fundamental mechanisms and characteristics of a foaming process, such as the requirement of generating a single- phase solution of polymer and blowing agent inside the extruder, the function and necessity of an adequate pressure-drop at discharge and expanding behaviour. This session also presents a selection of equipment for different extrusion processes. Basic information on “processing differences between diverse thermoplastics in process” and “the action of physical blowing agents and the influence of nucleating agents” concerning the achievement of fine and microcellular cell sizes will be explained. Biography Sebastian Schraube joined Leistritz Extrusionstechnik GmbH in March 2015 as a Process Engineer. He obtained his Mechanical Engineering Diploma in the field of plastics engineering at the Hochschule Darmstadt. During his studies, he participated in an international research programme on polymer-based composites and specialised in the analysis and optimisation of extrusion processes of polypropylene foams.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Parallel Track I: Polymer & Composites Dassault Systèmes Additive Manufacturing Strategy Dr Mike Sheh Senior Director SIMULIA Asia Pacific Abstract Additive Manufacturing, also known as 3D printing, is a manufacturing technology that has been evolving since the 1980s. Recently, there has been a tremendous surge in its popularity due to technological advancements. These brought 3D Printing to the desktop through the Maker Movement and enabled expansion beyond rapid prototyping of industrial applications for tool production and direct part production. The technology has offered designers the freedom to create shapes and meet functional requirements without the limitations of conventional manufacturing techniques. In this session, an overview of Dassault Systemes’ end-to-end solution for functional generative design, additive manufacturing process simulation, and an online additive manufacturing hub will be presented. Biography Mike Sheh is the Senior Director of SIMULIA Asia Pacific at Dassault Systèmes. He is responsible for all SIMULIA teams’ field operations across Asia Pacific. Prior to his current position, he was a leader of the SIMULIA’s World Team for Simulation Lifecycle Management (SLM) in 2012 – 2013 and was responsible for worldwide sales and implementation. During that period, Mike significantly expanded SIMULIA’s SLM presence in the global market. Mike has been with Dassault since 2008 after the acquisition of his prior employer, Engineous Software Inc which was the developer of the world’s leading process integration and automation system FIPER. At Engineous, Mike was responsible for marketing, Worldwide Automotive Sales, and later European Operations. Under his leadership, he has promoted FIPER technology adoption across automotive, turbo machinery, and aerospace industries. From 1993 to 1998, Mike was the Marketing Director at Cray Research Inc, and Silicon Graphics Inc, the world’s leading super computer and graphics vendor. Prior to Cray, Mike worked in General Motors Corp where he pioneered simulation and innovative testing since 1988. Mike received his PhD from the Department of Aeronautical and Aerospace Engineering of the University of Cincinnati. He has published over 25 technical papers in diverse fields on soft tissues mechanics, modelling of nonlinear behaviour of high temperature super alloy, vehicle crash simulation, design optimisation, and design for six sigma. He has conducted numerous speeches worldwide and was featured in Business Week’s Industry Insider in June 2003.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Parallel Track I: Polymer & Composites Science-based Generative and Functional Design and Global Production System for Additive Manufacturing Mr Olivier Hardy Global Account Aerospace & Denfense Expert Sales Manager Dassault Systèmes Abstract Additive manufacturing technologies empower designers to create products that were impossible to manufacture in the past using subtractive processes. However, significant challenges exist in the reliability and predictability of a number of Additive Manufacturing processes. These challenges are barriers to part certification and a much larger potential adoption in industry. This session will present an end-to- end workflow, starting with generative design, optimisation considerations for additive manufacturing, material processing and the layer-wise simulation of the process to predict stresses and distortions. Biography Olivier Hardy joined Computational Mechanics Company (COMCO) to develop nonlinear solvers (CFD, Structure, Multi Phase Flow). COMCO was later acquired by Altair Computing and Olivier started his career selling FEA software (pre and post optimisation). Olivier Hardy joined Engineous Software, a spin-off from GE, in 2008 and started focusing on process integration & design optimisation for large Aerospace and Automotive Corporations. In parallel, he completed his Masters in Technology Commercialisation at UT Austin McCombs Business School. He returned to France to grow Engineous activities in Europe in 2002. This led to the adoption of Engineous enterprise solutions inside Renault, PSA, Airbus Group, Rolls Royce. Engineous was acquired by Dassault Systèmes (DS) in 2008 where he joined DS’ Simulation Lifecycle Management practice. Since 2014, he oversees DS simulation activities inside AIRBUS Group and SAFRAN Group, and positions DS solution for Additive Manufacturing as the preferred solution in both groups. Olivier holds a Masters in Aerospace Engineering from ENSMA in France. He received his Masters on Engineering Mechanics from UT Austin where he worked under JT Oden on 3D adaptive HP Finite Element Method.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Parallel Track II: Light Metal & Alloys Key Technology Lecture: Understanding the Fatigue Response of Lightweight Metallic Alloys Professor Alexander Korsunsky Department of Engineering Science University of Oxford Abstract Light metallic alloys, based on Mg, Al and Ti, play an important role in advancing the lightweighting agenda across the industrial landscape from transportation to electronics. A crucial consideration in design concerns the fatigue response of these alloys. This is a complex phenomenon that spans nano- and micro-structural effects at the level of dislocation sub-structuring and twinning, the function of heat treatment and precipitate evolution, crack initiation and propagation in the short and long crack regimes, complex spectrum loading and the effects of overloads and underloads, crack closure and residual stress effects, and the formulation of predictive models for design. This session provides an overview for the work in this field that has been carried out over a decade of work in the University of Oxford, and the incorporation of the results in practice by their industrial collaborators. Biography Alexander Korsunsky is a Professor of Engineering Science at the University of Oxford and Trinity College. His research interests revolve around developing improved understanding of integrity and reliability of engineered and natural structures and systems, from high performance metallic alloys, polycrystalline ceramics to natural hard tissues. Alexander is also a consultant to Rolls-Royce on company design procedures for reliability and consistency of structural integrity. He has given keynote plenaries at international conferences and developed numerous international links, including Universitá Roma Tre (Italy), ENSICAEN (France) and the National University of Singapore. He has also co-authored on fracture mechanics (Springer) and elasticity (CUP), and published over 250 papers in scholarly periodicals on subjects ranging from neutron and synchrotron X-ray diffraction analysis and prediction of fatigue strength to micro-cantilever bio-sensors, size effects and scaling transitions in systems and structures. Alexander plays a leading role in the development of large-scale research facilities in UK and Europe. At Diamond Light Source (DLS, Harwell Oxford, UK), he chaired the Science Advisory Committee and the User Working Group for beamline I12 JEEP (Joint Engineering, Environmental and Processing). He is also on the editorial board of Journal of Strain Analysis (SAGE and IMechE, UK) and is a member of UK delegation to ESRF Council.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Parallel Track II: Light Metal & Alloys 3D Roll Forming of Sheet Metal - A New Method to Make Load Optimised Profiles with Variable Cross Sections Mr Albert Sedlmaier Managing Director data M Sheet Metal Solutions Abstract Automobile industry has set a long-term objective of substituting press formed parts by roll formed components because of their higher efficiency and flexibility. The session features the new flexible 3D roll forming technology which allows for the manufacture of profiles with variable cross sections by CNC controlled roll stands. This promising technology is suitable for high and ultra-high strength steels due to its simple bending operations along a line and the possibility of adjusting and calibrating the higher elastic springback of this material within the production line itself. This highly efficient production technology can be used to make profiles with load optimised contours and design structures in drastically reduced weight for cars and trucks or other applications. Due to its flexibility, various dimensions of parts can be produced with the same tooling by simple adaptation of respective CNC programmes and its respective roll tool paths. An industrial line for the manufacture of truck beams with double sided variable cross sections has been established at data M Sheet Metal Solutions as well as a research line for the manufacture of prototype parts for the automobile industry. The 3D roll forming technology also allows for the application of multi-material composites which consist of carbon fibre-reinforced thermoplastic tapes and steel sheets. This provides high process flexibility by using CNC controlled rolls and enables high production rates due to the high degree of automation. Biography Albert Sedlmaier received his Masters in Mechanical Engineering from the Technical University of Munich (TUM). Upon graduation, he started as a R&D officer at the Institute of Product Development at TUM in 1983 where he was in charge of education and research on CAD/CAM technologies as well as sheet metal roll forming. In 1987, he left TUM and started his own company, data M Sheet Metal Solutions GmbH. Albert is an active member in several scientific and industrial networks. He has participated and led several national and international research projects with partners in Europe, US and Asia.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Parallel Track II: Light Metal & Alloys Unlocking the Potential of Additive Manufacturing for Lightweight Design Dr Robert Yancey Vice President - Additive Manufacturing Altair Engineering Abstract Additive Manufacturing is receiving a lot of attention in the media and within organisations worldwide. It is clearly an interesting technology that spurs creativity and innovation from hobbyists to Corporate CEOs. As with any new technology, it can be daunting to move from just being ‘interesting’ to its actual practical implementation. This session will discuss the potential of additive manufacturing, its current limitations, and what has been done to overcome these roadblocks to move it from a cool technology to something that can make a difference in products that we use. One of the focus areas for Altair is providing the tools to create designs that take advantage of the many unique capabilities of additive manufacturing. Case studies and examples will be shared during the presentation. Biography Robert Yancey has technical background in composite materials, additive manufacturing, design optimisation, finite element modelling, and non-destructive evaluation. He has published extensively and is a frequent speaker at technical conferences and symposia. As a Vice President at Altair, he oversees the company’s overall efforts and strategy in the Additive Manufacturing domain. Robert is also an Affiliate Professor at the University of Washington in the Aeronautics and Astronautics Department where he lectures on Additive Manufacturing for Aerospace. He holds a Bachelor in Aeronautics and Astronautics from MIT, a Masters in Engineering Mechanics from Virginia Tech, and a PhD in Materials Engineering from the University of Dayton.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Parallel Track II: Light Metal & Alloys Lightweight Design Optimisation of Steel Structures for Marine and Offshore Vessel Application Mr Esko Karvonen Vice President, Offshore Deck Machinery Division MacGregor Pte Ltd, Singapore Abstract MacGregor is a leading company within the marine industry. This presentation from the MacGregor’s Offshore Deck Machinery Division (ODM) shows how iterative FEM-methods can be used to reduce the weight of heavy steel structures within the marine segment. For offshore vessels, the safety and reliability of the equipment is of highest priority. This priority has resulted in over-conservative and heavy steel structures. Together with SIMTech, MacGregor’s ODM has made a pilot study with a different approach to the design process. Once the boundary load cases, safety factors, class rules and main dimensions are set, an iterative FEM process will calculate how an ideal shape would look like for the mechanical stress problem. The FEM will create an organic shape with a minimum amount of material. From this initial stage, there is a need to change this geometry into something that is possible to produce with normal production methods. Both casted structures and welded sheet metal parts have been in the scope of this project. Biography After graduating in 1990 as a Naval Architect from the University of Applied Sciences in Turku, Finland, Esko Karvonen has worked in various positions within MacGregor. Esko first started in design. He was rotated to purchase and production in 1991 and subsequently took on a leadership role in MacGregor container ship solutions. During 2007 – 2014, Esko led the global hatch cover and container securing division. He moved to head the Offshore Deck Machinery division in 2015.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Parallel Track II: Light Metal & Alloys Rotary and Linear Friction Welding of Lightweight Materials Mr Alexander Wick General Manager KUKA Industries Abstract Friction welding is a solid state bonding process that gives parent material properties to bonded joints. This is done without wires, fillers or gases offering an environmentally friendly process. Friction welding is also the preferred method of joining dissimilar materials and, in some cases, the only possible option. Linear friction welding is the latest development in the friction welding arena that offers faster welding with materials of any geometry. Initially developed for the aerospace industry, it has now been adopted in other industries and applications. This presentation explains the process, applications and areas of development of linear friction welding with a focus on lightweight materials. Biography Alexander Wick joined KUKA Industries in January 2009 and since February 2012, acts as the General Manager of KUKA Industries – Reis Robotics Singapore Pte Ltd. Apart from his current role, Alexander also holds the position of the statutory director in the board of KUKA Industries in Singapore and is part of the International Management Team. KUKA Industries is one of the leading global companies in robot technology and system integration in various industry sectors such as Oil & Gas, Marine & Offshore, Automotive, Heavy Machinery and Structure Building. The company designs and executes complete automation systems as a turnkey supplier for many different process applications in the areas of Welding (GMAW and Friction Welding), Oxy-fuel Cutting, Laser Welding and Cutting, Casting, Photovoltaics and Battery production. Prior to joining KUKA Industries, Alexander held various management positions as Chief Representative, Sales Manager and Regional Manager for companies in China and Germany. He is a mechanical engineer by training and received two master degrees in business administration from the National University of Singapore and UCLA Anderson School of Management.

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Parallel Track II: Light Metal & Alloys Parallel Track II: Light Metal & Alloys Rotary and Linear Friction Welding of Lightweight Materials Carpenter Technology Advanced Material Mr Jose Carranza Vega Regional Metallurgist, Asia Pacific Carpenter Technology Asia Pacific Pte Ltd Abstract Carpenter is a leading international manufacturer and distributor of specialty alloys and engineered products in various markets like aerospace, medical, industrial, consumer, automotive and energy. Selecting materials involves taking many factors into consideration. One factor is meeting the demand for fewer defects, longer service life, and reduced maintenance and operating costs. Another factor is to meet customers’ desire for cheaper parts and components, which leads to lower life cycle cost. A third factor focuses on the need for “greener” components that are more environmentally friendly, for example, those that eliminate the need for surface treatment. Carpenter has developed several materials that have better performances compared to conventional materials. These materials also enabled cost reduction due to their reduced design footprints and meeting the demands for longer service and lower life cycle costs. The presentation will introduce participants to these materials which have benefited many. Biography Jose Carranza Vega has more than 6 years of experience in the field of Specialty Alloy. He has collaborated with multi-disciplinary/multi-cultural technical teams addressing new applications, new product development, material specification set ups, customisation of products, conducting technical seminars, failure analysis and quality product claim handling. Jose’s experience has been focused on processes such as forging, machining, surface treatments, ring rolling, heat treatments and further manufacturing variations in restrictive applications. As a regional metallurgist, Jose is a key resource to Carpenter, and he is responsible for managing all technical and quality subjects associated with Carpenter’s customers, products and developments.

Acknowledgements The Organising Committee of SIMTech AMF’16 thanks the following organisations for their support and collaboration: Partners: In Collaboration with: Exhibitors:

List of Exhibitors Altair Engineering Sdn Bhd ESI GROUP B3-10-7 Plaza Sentral, Jalan Stesen Sentral 5, Fraser Business Park KL Sentral, Kuala Lumpur 50470, Malaysia ROAP Office, N° 20-2 (2nd floor) Jalan Metro Pudu Tel: +60 3 2742 7890 | Fax: +65 6444 3706 Kuala Lumpur 55100 Email: [email protected] Tel: +603 2857 1572 Website: www.altairasean.com Email: [email protected] Website: www.esi-group.com aNexus Pte Ltd 20 Sin Ming Lane, #08-53, Midview City Hong Chek Co Pte Ltd Singapore 573968 180 Paya Lebar Road, #09-07 Yi Guang Factory Building, Tel: +65 6365 5028 | Fax: +65 6365 5450 Singapore 409032 Email: [email protected] Tel: +65 6746 1308 | Fax: +65 6747 1760 Website: www.anexuscorp.com Email: [email protected] Website: www.hongchek.com Autodesk Asia Pte Ltd 3 Fusionopolis Way, #10-21 Symbiosis, 138633 Jebsen & Jessen Technology Pte Ltd Tel: +65 6461 8100 | Fax: +65 6461 8382 18 Enterprise Road, Singapore 629824 Email: [email protected] Tel: +65 6305 3688 | Fax: +65 6305 3699 Website: www.autodesk.com Email: [email protected] Website: www.technology.jjsea.com Carpenter Technology Asia Pacific Pte Ltd No 1 Grange Road, #05-05, Orchard Building, KUKA Industries Reis Robotics Singapore Singapore 239693 Pte Ltd Tel: +65 6738 2401 | Fax: +65 6734 7983 10C Enterprise Road, Singapore 629829 Email: [email protected] Tel: +65 6686 3989 | Fax: +65 6686 3975 Website: www.cartech.com Email: [email protected] Website: www.kuka-industries.com Creatz3D Pte Ltd 180 Paya Lebar Road, #08-07 Yi Guang Factory Building Leistritz Asia Extrusion Pte Ltd Singapore 409032 25 International Business Park, Singapore 609916 Tel: +65 6631 8555 | Fax: +65 6747 1760 Tel: +65 6562 8142 Email: [email protected] Website: www.leistritz.com Website: www.creatz3d.com.sg Email: [email protected] Dassault Systèmes Singapore Pte Ltd LMS Technologies Pte Ltd 9 Tampines Grande, #06-13, Singapore 528735 20 Sin Ming Lane, #05-59 Midview City, Tel: + 65 6511 7988 | Fax: +65 6511 7989 Singapore 573968 Email: [email protected] Tel: +65 6451 1123 | Fax: +65 6452 1011 Website: http://www.3ds.com Email: [email protected] Website: www.lmsscientific.com data M Sheet Metal Am Marschallfeld 17 MOS Pte Ltd D-83626 Oberlaindern/Valley 66 Horne Road, #03-00, Singapore 209073 Tel: +49 (8024) 640-0| Fax: +49 (8024) 640-300 Tel: +65 6273 8515 | Fax: +65 6273 8125 Email: [email protected] Email: [email protected] Website: www.datam.de Website: www.mosgrp.com Eco-Space Pte Ltd Product Development Solutions Pte Ltd 5002 #01-04 Techplace II, Ang Mo Kio Ave 5, 305 Alexandra Road, #05-01/02 Singapore 569871 Vantage Automotive Centre Singapore 159942 Tel: +65 6484 6977 Tel : +65 6732 9818 | Fax : +65 6736 2028 Email: [email protected] Email: [email protected] Website: www.eco-space.com.sg Website: www.pdsol.com Employment and Employability Institute (e2i) 80 Jurong East St 21, Singapore 609607 Tel: +65 6474 0606 | Fax: +65 6566 9097 Email: [email protected] Website: www.e2i.com.sg EOS Singapore Pte Ltd 8 Admiralty Street, #06-12/13 Admirax, Singapore 757438 Tel: +65 6430 0552 | Fax: +65 6430 0549 Email: [email protected] Website: www.eos.info

Lightweight Materials and Technologies: Trends, Applications and Opportunities for Manufacturing Contact Us: Singapore Institute of Manufacturing Technology 2 Fusionopolis Way, #08-04, Innovis, Singapore 138634 Tel: (65) 6501 1800 | Fax: (65) 6250 3659 Web: www.SIMTech.a-star.edu.sg