Manufacturing and Materials - P18311998

WINTER ISSUE

MANUFACTURING & MATERIALS TECHNOLOGY EDUCATION & TRAINING GUIDE

February - December 2019

FEATURED COURSES INCLUDE: • NEW! Introduction to Additive Manufacturing | Page 10

• NEW! AS13000 Problem Solving Requirements for Suppliers | Page 12 • NEW! Basics of Silicone Rubber Science and Technology | Page 14 • NEW! Introduction to Rubber Science and Technology | Page 16 • NEW! Fuels Systems: Materials Selection and Compatibility with Alternative Fuels | Page 22 • NEW! Adhesives Course Bundle | Page 28

PLUS—Explore Related Manufacturing & Materials Technology Resources on pages 38-39!

sae.org/learn/

HOWDOYOU STAY UP-TO-DATE AND SECURE TIMELY INFORMATION IN YOUR TECHNOLOGY FOCUS AREA? Look to SAE International as your most critical resource for lifelong training and professional development. In this issue of the Manufacturing & Materials Technology Education and Training Guide , you’ll find an extensive portfolio of courses designed to keep you ahead of the industry. PLUS - don’t miss the suggested Related Manufacturing & Materials Technology Resources on pages 38-39. We’ve selected key SAE books, standards, journals, and technical events to further your professional development and deepen your technical knowledge. THIS GUIDE INCLUDES EDUCATION & TRAINING AND KNOWLEDGE RESOURCES IN THE FOLLOWING TOPIC AREAS: • Manufacturing • Materials • Metallurgy

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“The instructor presented the material in an enthusiastic and understandable way.” Susan Collet Senior Principal Engineer, Materials Engineer; Toyota Techical Center USA, Inc.

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A LEARNING FORMAT TO FIT EVERY NEED

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learning formats to accommodate diverse learning styles. Explore classroom, live and online, and on-demand courses. Many courses are oered in multiple formats to fit your exact need. Be sure to watch for the icons that identify the format available for each course. Seminars or workshops available as similar live, online web seminars or on-demand courses, will feature icons and information about the schedule and fees for all platforms.

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TABLE OF CONTENTS

3 3 4 6

MANUFACTURING

Design for Manufacturing & Assembly (DFM/DFA)

Metal Forming

Additive Manufacturing On Demand Course Bundle

8 Design for Additive Manufacturing: Towards End-Part Production 10 NEW! Introduction to Additive Manufacturing 12 NEW! AS13000: Problem Solving Requirements for Suppliers

14 MATERIALS 14 NEW! Basics of Silicone Rubber Science and Technology 16 NEW! Introduction to Rubber Science and Technology 18 Materials Degradation in Mechanical Design: Wear, Corrosion, Fatigue and their Interactions 20 Fundamentals of Threaded Fasteners 22 NEW! Fuels Systems: Materials Selection and Compatibility with Alternative Fuels 24 Automotive Plastics: Principles of Materials and Process Selection 25 Brake Friction Materials: Testing, Quality and Selection Seminar 26 Corrosion Engineering and Prevention Seminar 28 NEW! Adhesives On Demand Course Bundle 30 Introduction to Advanced High Strength Steel Applications and Manufacturing Seminar 31 Material Selection and Testing for Plastics Seminar 32 Vehicle Sound Package Materials 33 Sound Package Materials for Vehicle Noise Control Seminar 34 Surface Texture: Specification and Control Seminar

36 METALLURGY ON DEMAND COURSES

38 RELATED MANUFACTURING & MATERIALS TECHNOLOGY RESOURCES

39 SEMINARS HELD IN CONJUNCTION WITH WCX19

40 2019 LIVE LEARNING SCHEDULE

To help you better plan your training, we schedule live course oerings as far in advance as possible. The content in this resource guide reflects the most accurate information available at the time of publication. Rarely, unforeseen circumstances may force a change to the schedule. Early registration ensures that you not only have a spot in your selected course but are notified of any changes. For the most-up-to-date listing of scheduled courses, visit sae.org/learn/professional-development/ . SAE International reserves the right to cancel oerings and cannot be held responsible for costs incurred beyond registration fees.

DESIGN FOR MANUFACTURING & ASSEMBLY (DFM/DFA) MANUFACTURING

“This course delivers what it says and keeps you engaged with hands-on exercises. I strongly recommend this course to any engineer; this will definitely broaden their scope and insight at work. Thank you SAE.”

Correctly applied, DFM+A analysis leads to reductions in production cost, without compromising product time-to-market goals, functionality, quality, serviceability, or other attributes. You will learn the Boothroyd Dewhurst Method and how to apply it to your own product design. Information on how DFM+A fits in with QFD, concurrent and robust engineering, and other disciplines is included. You will receive and use the reference textbook, Product Design for Manufacture and Assembly, written by Georey Boothroyd, Peter Dewhurst and Winston Knight. LEARNING OBJECTIVES By attending this seminar, you will be able to: • Perform Design for Assembly (DFA) Analysis using the BDI Manual (Worksheet) Method • Perform DFM Analysis (manufacturing cost estimation) • Apply Design for Service (DFS) Principles • Reduce your company’s production costs by analyzing and eliminating the factors that greatly aect the time, cost, and quality of manufacturing, assembly and service processes • Utilize eective analysis, brainstorming, and trade-o techniques for redesigning assemblies and subassemblies • DFA Good Design Principles • DFA Baseline Analysis Exercise • Redesign Project (Pneumatic Piston Assembly) • General Approach to Manufacturing Cost • Estimation • BDI Design for Manufacture (DFM) Cost Estimation • Design for Service (DFS) Assessment • BDI DFM/A Software Toolkit Demonstration • DFM+A Workshop Checklist • Brainstorming Guidelines • DFM+A Workshop Project • Institutionalizing DFM+A in Your Organization INSTRUCTOR Kevin Zielinski Owner and Operator, Red Cedar Media, LLC CONTENT HIGHLIGHTS • What is DFM+A

Praneeth Gandi Sr. R&D Design Engineer Tranter

I.D.# 92047

SCHEDULE February 27-28, 2019 Troy, Michigan June 26-27, 2019 Troy, Michigan November 19-20, 2019 Troy, Michigan

FEES List:

$1,595 $1,436

Members:

TWO-DAYS/1.3 CEUS

Get the complete course description and register: sae.org/learn/ content/92047

BRING THIS COURSE TO YOUR LOCATION. CONTACT SAE CORPORATE LEARNING SOLUTIONS TO LEARN MORE. +1.724.772.8529 Visit sae.org/learn/ and select CORPORATE LEARNING

3 ways to get a no-obligation price quote to deliver a course to your company Call SAE Corporate Learning at +1.724.772.8529 | Fill out the online quote request at sae.org/corplearning Email us at Corplearn@sae.org

METAL FORMING

“The instructor makes the class very educational and enjoyable.”

This seminar covers metal forming and related manufacturing processes, emphasizing practical applications. From forged or P/M connecting rods to tailor-welded blank forming, metal parts are integral to the automotive industry. As a high value-adding category of manufacturing, metal forming is increasingly important to the core competency of automobile manufacturers and suppliers. A thorough survey of metal forming processes and metal forming mechanics will be performed, including bulk deformation, sheet- metal, and powder metallurgy operations. Design considerations are fully integrated into the course and are presented with every process. A large number of real-world case studies are presented to the attendees to emphasize course content. You will receive a copy of the book Manufacturing Engineering Technology, co-written by instructor Steven R. Schmid. LEARNING OBJECTIVES By attending this seminar, you will be able to: • Identify the unique characteristics of metals that lead to plastic deformation as a processing strategy • Explain the processes involved in metal forming mechanics, materials, and tribology • Analyze the interrelationships between various factors that influence the quality of manufactured products • Describe sheet metal characteristics and forming • Describe the wide variety of processes used to shape and deform metals, including forging, rolling and extrusion; sheet metal forming, shearing and stamping; powder metallurgy processes and assorted other processes WHO SHOULD ATTEND This course is designed for engineers who are involved in metal forming and other related manufacturing processes. CONTENT HIGHLIGHTS • Overview of Solid Mechanics and Materials Science Topics of Importance to Metal Forming • Tribology of Metal Forming: Friction, Lubrication and Wear

Michael Telenko, Jr. Engineering & Design Manager Shiloh Industries/MTD Automotive

I.D.# 85012

SCHEDULE Future oerings are being scheduled. Check the course web page for the most up-to-date schedule and information.

FEES List:

$1,650 $1,485

Members:

TWO-DAYS/1.3 CEUS

Get more information and register: sae.org/learn/content/85012/

TRAIN YOUR WHOLE TEAM. CONTACT SAE CORPORATE LEARNING SOLUTIONS. +1.724.772.8529 Visit sae.org/learn/ and select CORPORATE LEARNING

• Bulk Deformation Processes • Sheet Metal Forming Process • Powder Metallurgy Process INSTRUCTOR Steven R. Schmid Professor, University of Notre Dame

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SAE ENGINEERING ACADEMIES Immersive training covering core engineering topics. Cost-eective and time-ecient educational programs taught by experts dedicated to helping the industry.

• Aerospace Executive Development • Diesel Engine Technology • Engineering Management • Hybrid and Electric Vehicle • Transmission

• Vehicle Noise Control • Workforce Readiness

Visit sae.org/learn/professional-development and browse Instructor-Led Learning

P18275505

The Additive Manufacturing On Demand Course Bundle from training partner ToolingU-SME guides you through essential topics in the understanding and application of Additive Manufacturing. Successful completion provides the knowledge needed to begin eectively using AM technology. These courses explain the fundamental concepts of additive manufacturing, including the main principles behind AM and the safety precautions to take during the process. They also introduce the basic steps in additive manufacturing and discuss the variety of methods and materials used to create AM products. ADDITIVE MANUFACTURING COURSE BUNDLE Course titles listed are available only as part of the Additive Manufacturing Course Bundle

COURSE TITLES: INTRO TO ADDITIVE MANUFACTURING

This course introduces users to additive manufacturing (AM) processes by outlining the history of AM, describing AM technology, and exploring current and future additive manufacturing applications: ADDITIVE MANUFACTURING SAFETY This course describes the various safety hazards involved in additive manufacturing (AM) and the precautions operators should follow to protect themselves. Operators must be aware of hazards as well as the safety protocols used to reduce them. THE BASIC ADDITIVE MANUFACTURING PROCESS This course provides an overview of the build process used in additive manufacturing. Upon completing “The Basic AM Process,” users should know the eight basic steps involved in creating an AM product. ADDITIVE MANUFACTURING METHODS AND MATERIALS This course provides an overview of the dierent processes used in additive manufacturing. This class also details the materials used in each process and any additional considerations specific to those materials. DESIGN FOR ADDITIVE MANUFACTURING This course discusses how to conceptualize and create a part design for an additive manufacturing (AM) process. After taking this course, you will understand key DFAM concepts, such as functional complexity and hierarchical complexity, the basics of AM production processes, and how DFAM concepts related to basic AM production.

ADDITIVE MANUFACTURING MATERIALS SCIENCE This course provides a comprehensive

I.D.# PD281743

SCHEDULE On Demand/90-day Access

overview of the materials that can be used with additive manufacturing (AM) processes. After completing this course, you will not only be able to distinguish between thermoplastic and thermoset polymers, ferrous metals and nonferrous alloys, and ceramic and composite materials, but also be able to determine which material type is most appropriate for use with a specific AM process. INTEGRATING ADDITIVE MANUFACTURING WITH TRADITIONAL MANUFACTURING This course discusses the factors manufacturers should consider when adding an additive manufacturing (AM) component to a traditional manufacturing operation, including cost, logistics, and best uses of AM with traditional manufacturing, among other concerns. ADDITIVE MANUFACTURING AS A SECONDARY PROCESS This course provides a comprehensive overview of the way in which manufacturers can use additive manufacturing (AM) as a secondary, or indirect, process. Knowledge about AM secondary processes and their benefits is important in order to understand the full impact that AM has upon traditional manufacturing. Upon completion, you will be able to identify the traditional manufacturing areas that benefit from using AM as a secondary process and the advantages and disadvantages of doing so.

FEES List:

$470 $423

Members:

EIGHT-HOURS

Get the complete course description and register: sae.org/learn/content/pd281743/

DEVELOPER ToolingU-SME

DESIGN FOR ADDITIVE MANUFACTURING: TOWARDS END-PART PRODUCTION

One of the biggest challenges companies have is in getting their designers to embrace AM since most of the designers did NOT formally study AM and school curriculums are only now beginning to add courses in AM

This web seminar fills a gap between designers that are familiar with design tools and the emerging technologies of Additive Manufacturing, which are mostly in the manufacturing domain in most organizations. The goal of this course is to give designers the information they need to start designing for AM at all levels –identifying and justifying use of AM technology for a particular part, selecting the right process and material for the application in mind and ensuring it is designed with the advantages and considerations of AM in mind. The course is not intended to serve as a software- training class or as a deep dive into any specific AM process, but rather to draw connections between design and AM from a designer’s perspective. LEARNING OBJECTIVES By attending this seminar, you will be able to: • List the dierent polymer and metal AM process technologies and materials and identify which of these are being used for functional part production • Select the optimum AM material and process for a particular application • Predict how design decisions impact manufacturability for the selected AM process and apply design rules and guidelines to your design process • Quantify the expected properties of the AM parts you are designing • Discover how topology optimization, cellular structures and other disruptive design techniques can be leveraged with AM and associated software tools • Identify the dierent drivers for adopting AM for a particular part, with regard to cost, lead time, supply chain and performance risks • Relate to the challenges and ongoing research eorts to be able to move forward with AM implementation in the presence of rapid change in the field • Develop a comprehensive strategy to bring AM for functional part production into your organization that addresses both the benefits and impacts WHO SHOULD ATTEND Designers working in aerospace or ground vehicle chartered with designing next generation solutions, designing replacement parts, or designing tools used in the manufacturing process will benefit from this course.

CONTENT HIGHLIGHTS • Additive Manufacturing Processes • Introduction to AM • Polymer AM • Metal AM • Materials Options and Selection • Key Process Concepts • Considerations • Introduction to Design for AM • The Need for New Design Thinking with AM • Four Levels of AM Design • Introduction to Software Tools for AM • Support Fundamentals • Build Preparation Software Demos • Topology Optimization • Motivation: The Case for Sustainable Design • Case Studies with AM • Introduction to Optimization Concepts • Material Models • Classification of Cellular Materials • Functions and Performance Gains • Case Studies with AM • Modeling Approaches • Demo with nTopology • Manufacturability • Implementing AM - A Practical Guide for Designers • Part Selection for AM • Challenges and Open Questions • Successful AM Adoption Transition Strategies • Resources • Demo with ANSYS • Manufacturability • Lattice Materials Design • Biometric Underpinnings

I.D.# WB1705

SCHEDULE June 3-12, 2019 Live Online September 9-18, 2019 Live Online

FEES List:

$720 $648

Members:

FIVE, 2-HOUR SESSIONS/1.0 CEUS Get more information and register: sae.org/learn/content/wb1705/

FIND OUT HOW TO TRAIN YOUR ENTIRE TEAM. CONTACT SAE CORPORATE LEARNING SOLUTIONS. +1.724.772.8529 Visit sae.org/learn/ and select CORPORATE LEARNING

INSTRUCTOR Dhruv Bate Associate Professor, Arizona State University

NEW! INTRODUCTION TO ADDITIVE MANUFACTURING

Pre-requisites: Prior CAD experience recommended. Some experience viewing CAD files online. A basic understanding of the purpose and uses of CAD programs.

Additive Manufacturing (AM) is a growing segment of advanced manufacturing, because it provides innovative solutions to traditional manufacturing suppliers of the aerospace, medical and automotive industries. Traditionally thought of as small volume and prototyping technology, additive manufacturing is an emerging technology that can be utilized to produce millions of parts per year. This course introduces the skills and knowledge necessary to understand the benefits of additive manufacturing, through hands on experiences with software and additive manufacturing machines. Additionally, the course reviews the numerous technologies associated with additive manufacturing, and it examines economic barriers. LEARNING OBJECTIVES By attending this seminar, through a hands-on experience, you will be able to: • Identify current additive technologies • Describe the part design approach • Explain how to manage and control undesirable and unintended variability • Describe tooling via 3D printing • Identify barriers to utilizing Additive Manufacturing • Explain new technologies and emerging research in Additive Manufacturing WHO SHOULD ATTEND This is an introductory course designed for engineers and technologists who would like to understand the fundamentals of design for additive manufacturing. Individuals in other professional disciplines who are interested in enhancing their knowledge in this arena will also find this course helpful.

CONTENT HIGHLIGHTS DAY ONE: • Introductions • History and Purpose

I.D.# C1861

SCHEDULE Future oerings are being scheduled for this course. Check the course web page for the most up-to-date schedule and information.

• Additive Manufacturing Technologies Overview and Videos (Process Details, Advantages, and Limitations) • General Setup Procedure Refresher and Overview for printing part demonstratio • Day 1 Demonstration via Solid Works Group Design, Validate, Print Activity hands on activities • Discussion and Wrap-up DAY TWO: • Design Overview: Part Design Approach – Managing and Controlling Undesirable and Unintended Variability • Day 2 Demonstration via Solid Works • Group Design, Validate, Print Activity • Group Discussion, Lessons learned on Day 1 and Day 2 Group Activities • Tooling via Additive Manufacturing • Application Overview and Use Case • Discussion on Barriers to Adoption of Additive Manufacturing • Emerging Research (hybrid, multi- process, inspection, in-site monitoring) • America Makes Road-mapping Overview • Business Overview • Discussion and Wrap-up

FEES List:

$1,950 $1,950

Members:

TWO-DAY/1.3 CEUS

Get the complete course description and register: sae.org/learn/content/c1861/

TRAIN YOUR WHOLE TEAM. CONTACT SAE CORPORATE LEARNING SOLUTIONS. +1.724.772.8529 Visit sae.org/learn/ and select CORPORATE LEARNING

INSTRUCTOR David Pierson Senior Design Engineer MAGNET

NEW! AS13000: PROBLEM SOLVING REQUIREMENTS FOR SUPPLIERS

I.D.# C1862

AS13000 defines the Problem-Solving standard for suppliers within the aero-engine sector, with the Eight Disciplines (8D) problem solving method the basis for this standard. This two-day course provides attendees with a comprehensive and standardized set of tools to become an 8D practitioner and meets all the requirements of the training syllabus in AS13000. Successful application of 8D achieves robust corrective and preventive actions to reduce the risk of repeat occurrences and minimize the cost of poor quality. This is essential to enable long term customer - supplier relationships and positively contributes towards zero defects and customer satisfaction. This course includes deployment guidance, practical application exercises of the toolkit and step by step guidance on each of the 8 disciplines. LEARNING OBJECTIVES By attending this seminar, you will be able to: • Lead and Facilitate an 8D Problem Solving Activity to AS13000 Requirements • Complete an AS13000 8D Problem Solving Template • Apply a Problem-Solving Toolkit • Recognize and deal with issues of Team Dynamics and Challenging People • Practice Eective Customer / Stakeholder Management • Reduce Risk of Problem Recurrence CONTENT HIGHLIGHTS DAY ONE • Introduction • Problem Solving Infrastructure • D0 Implement Immediate Containment and Prepare for 8D • D1 Form the Team • D2 Define the Problem

SCHEDULE January 31-February 1, 2019 Birmingham, United Kingdom March 4-5, 2019 Bloomfield, Connecticut June 13-14, 2019 Birmingham, United Kingdom

FEES List:

$1,415 $1,274

Members:

TWO-DAY/1.3 CEUS

Get the complete course description and register: sae.org/learn/content/ c1862/

TRAIN YOUR WHOLE TEAM. CONTACT SAE CORPORATE LEARNING SOLUTIONS. +1.724.772.8529 Visit sae.org/learn/ and select CORPORATE LEARNING

• D3 Develop Containment Actions • D4 Identify and Verify Root Causes DAY TWO • D5 Identify Corrective Action • D6 Implement Corrective Action • D7 Define and Plan Preventive Action • D8 Recognize the Team

• Course Reflection • Course Assessment INSTRUCTOR Suzanne Hill

Founding Director and Quality Executive Assured Quality Improvements Limited

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P151640

MATERIALS

NEW! BASICS OF SILICONE RUBBER SCIENCE AND TECHNOLOGY

Prerequisites: Participants should have a college degree with basic engineering and chemistry.

Silicone rubber is comprised of inorganic-organic polymers. These materials consist of an inorganic backbone with organic side groups attached to silicon atoms. This family of polymers possesses unmatched versatility giving the formulator and user multiple forms and methods to cross link the polymers into rubber materials having the widest service temperature range of any rubber material. This course is designed to provide the participant with a thorough understanding of silicone’s engineering characteristics. This class will take you from creation of silicone from sand through formulating the compound and the various methods by which silicone can be fabricated into useful service articles. Silicone rubber is used in the design and manufacture of automotive gaskets, O-rings, aerospace seals, industrial static seals, appliance seals, plate seals and molded and extruded seals and gaskets. The instructor will address the dierences between high consistency rubber, caulks, and the various liquid silicone rubbers. This class is suitable for those individuals having various degrees of knowledge in silicone materials and applications. LEARNING OBJECTIVES At the completion of the course the attendee will be able to: • Explain the dierences between silicone rubber and other rubber materials • Discuss the influences of specific silicone polymer architecture on engineering properties • Formulate the corrective additives to influence specific performance attributes • Compare the dierences between the various types of silicone rubbers • Contrast the dierent silicone rubber curing and fabrication systems • Describe the engineering characteristics that make silicone rubber unique • Recognize when to use silicone rubber in an application • Apply the principles presented in this course to improve the quality of silicone rubber articles WHO SHOULD ATTEND This course is structured to benefit all those who design, make, buy or sell rubber articles manufactured from silicone rubber. The seminar will enhance the knowledge of those who have some level of experience and will provide a firm foundation for those who are new to working with silicone rubber, procuring or selling this unique material.

CONTENT HIGHLIGHTS • What are silicones • How are they made • Dierences between silicone rubber and other rubber materials • What makes silicone rubber unique and when to use it instead of other rubber materials • Influence of additives during construction of the silicone rubber compound • Essential dierences between high consistency and low viscosity and liquid molding • Types and influence of dierent cure systems • Manufacturing of silicone rubber compounds • Fabrication technologies • Troubleshooting

I.D.# C1804

SCHEDULE May 20, 2019 Troy, Michigan October 7, 2019 Troy, Michigan

FEES List:

$835 $752

Members:

ONE-DAYS/.7 CEUS

Get the complete course description and register: sae.org/learn/content/c1804

INSTRUCTOR F. J. (Joe) Walker Owner of Elastomer Technologies

NEW! INTRODUCTION TO RUBBER SCIENCE AND TECHNOLOGY

Prerequisites: Participants should have a college degree with basic engineering and chemistry.

Rubber – a loosely cross-linked network of polymer chains that when strained to high levels will forcibly return to at or near it original dimensions. This course is designed to provide the participant with a thorough understanding of rubber’s engineering characteristics. This class will introduce the various sources of rubber, both natural and synthetic. The class will contrast the dierences between rubber and plastics; including thermoplastic rubber. Detailed discussions on how to select the correct rubber polymer for the application, highlighting the pros and cons of each major rubber type. Rubber is used in the manufacture of automotive gaskets, oil seals, and rotating shaft seals; reciprocating seals; O-rings; pass through seals/gaskets; aerospace seals; and boots/bellows. The subject matter is well suited for both the novice as well as those who have some basic experience in the field. LEARNING OBJECTIVES At the completion of the course the attendee will be able to: • Demonstrate the dierence between natural rubber and synthetic rubber • Contrast the dierence between thermoset rubber and thermoplastics • Choose the correct rubber system for specific applications • Discuss the most common testing methods used to classify rubber characteristics • Describe and contrast the characteristics between dierent fabrication methods • Recognize the importance of cross-link density relative to rubber characteristics • Apply the principles presented to create specifications and improve the quality of rubber articles WHO SHOULD ATTEND This course is structured to benefit all those who design, make, buy or sell rubber products. The seminar will enhance those who have some level of experience and will lay a firm foundation for those new to working, buying or selling this complicated material.

CONTENT HIGHLIGHTS • What is rubber • How rubber is classified • How is rubber made • Dierence between natural and synthetic rubber • Rubber vs. Plastics: dierences • Rubber types • Establishing design targets • How to select the correct rubber type from design targets • Rubber formulating overview • Rubber mixing methods • Testing methods • Rubber curing • Cure state vs properties • Rubber fabrication • Product specifications

I.D.# C1812

SCHEDULE May 21, 2019 Troy, Michigan October 8, 2019 Troy, Michigan

FEES List:

$835 $752

Members:

ONE-DAYS/.7 CEUS

Get the complete course description and register: sae.org/learn/content/c1812

INSTRUCTOR Francis J. Walker Owner of Elastomer Technologies

MATERIALS DEGRADATION IN MECHANICAL DESIGN: WEAR, CORROSION, FATIGUE AND THEIR INTERACTIONS

This course summarizes the mechanisms that cause materials and mechnical components to degrade in service through exposure to deleterious mechanical and environmental conditions.

Materials degradation from environmental conditions is a common factor that will often occur in mechanical equipment used in every type of environment. These processes can frequently materialize in unpredicted and harmful ways, especially when they interact and lead to early component damage or failure. This five-session course will summarize the mechanisms that cause materials and mechanical components to degrade in service through exposure to deleterious mechanical and environmental conditions. The course is designed to develop knowledge of issues of material degradation in service and the eect upon the performance and reliability in the process of mechanical design. These processes include wear, corrosion, fatigue, and their interactions. The instructor will take a practical approach to the topics to allow participants to cite the causes of performance reduction. Potential solutions will be covered including material selection and material or design modifications that would improve component life and performance in a range of harmful environments or operating conditions. The review of each mechanism will include a presentation of the fundamental basis for these failure mechanisms, followed by practical examples of how they occur in reality. LEARNING OBJECTIVES By connecting with this web seminar, you will be able to: • Cite the typical wear mechanisms that occur in mechanical equipment and their causes • Cite the basic corrosion mechanisms and their causes • Identify the interactions that occur between wear, corrosion and fatigue • Suggest practical material or design solutions to those damage mechanisms WHO SHOULD ATTEND Engineers who design and process mechanical equipment; applications engineers involved in equipment or component design specific to an industrial application; materials, process and equipment development engineers; plant engineers; test engineers responsible for product or component testing and analysis of failed mechanisms; and quality engineers who establish methods and procedures for component reliability and analysis of failed components will benefit most from this course.

CONTENT HIGHLIGHTS Session 1 - Corrosion • Electrochemical cell • Galvanic series • Corrosion mechanisms: • Galvanic corrosion • Uniform attack

I.D.# WB1722

SCHEDULE April 9-23, 2019 Live Online October 8-22, 2019 Live Online

Session 2 - Corrosion (continued) • Corrosion mechanisms (cont.)

FEES List:

$720 $648

• Crevice corrosion/pitting • Stress corrosion cracking

Members:

• Eects of corrosion on component life • Corrosion solutions and prevention Session 3 - Wear

FIVE, 2-HOUR SESSIONS/1.0 CEUS

Get more information and register: sae.org/learn/content/wb1722/

• Adhesion • Abrasion Session 4 - Wear (continued) • Fretting

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• Tribo-corrosion • Fataigue wear • Erosion Session 5 - Lubrication • Theory and application and the eects on friction and wear INSTRUCTOR Michael Kim Principal Engineer, Tribological Materials, GGB Bearing Technology

SAE’S “TOTAL” STEM SOLUTION We are the only U.S.-based engineering organization to oer a full continuum of Kindergarten-College (K-16)science, technology, engineering, and math education opportunities. Learn how you can get involved at saefoundation.org.

FUNDAMENTALS OF THREADED FASTENERS

This is a basic course and will be best received by those wishing to gain a broad and basic understanding of the topic.

In this course, explore the basics of threaded fasteners, what purpose specific product design features address, the importance of proper material choices, and the function of platings and coatings. This course introduces you to basic fastener engineering principles and explains why tension is all-important in the bolted joint, the relationship between torque and tension, how screws can be used to form their own internal threads, and new technologies and practices being deployed by automotive manufacturers to achieve lighter weight products. This course includes a segment on joining technologies that enable automotive designers and manufacturers to succeed in their light weighting activities. Many of these technologies are relatively new and state-of- the art. • Distinguish the dierent characteristics of threaded fasteners and in what situations/applications those characteristics should be deployed • Explain the relationship between torque and tension in a bolted joint • Dierentiate various tightening strategies and assess the most appropriate for specific assembly operations • Distinguish between dierent material choices and how associated unique material properties lend the designer to use one material over another • Explain how high strength fasteners are achieved • Evaluate the many plating and coating options available for fasteners and make choices that provide the user the greatest amount of value and utility. • Explain the dierence between a traditional bolted joint and a joint formed by a thread forming fastener. You will be able to distinguish fundamental dierences between the fastener engineering that goes into thread forming in dierent materials • Evaluate di°cult joining scenarios posed by new assembly challenges and assess and apply new joining technologies that will successfully provide a solution WHO SHOULD ATTEND Engineers and non-engineers that are in a technical or semi- technical role, who either use, design-in, or provide others with guidance related to fasteners. Individuals that are new to the industry, have recently moved to a role that requires basic knowledge of fasteners and fastener engineering, or have been in the industry for a while but have never received formal education on fasteners or wish to improve their knowledge of fasteners. LEARNING OBJECTIVES By attending this seminar, you will be able to:

CONTENT HIGHLIGHTS Basics of Fastener Engineering • Considerations when designing a threaded joint • Tension versus shear joints • The Bolted Joint • Torque Tension Relationship • Tightening Strategies • Loss of tension/Locking Fasteners • Thread Forming Screws • Special Considerations in Thread Forming • Joining to Enable Lightweighting • Fastener Failure • Manufacturing Flaws -- Surface discontinuities Threaded Fastener Product Basics • How Fasteners are made - Video • Fastener Design Basics -- Design discussion– what are you designing for? • Screws and Bolts • Threads • Nuts • Washers • Fastener Materials • Heat Treating Fasteners • Plating and Coatings INSTRUCTOR Laurence Claus President, NNi Training and Consulting, Inc.

I.D.# C1733

SCHEDULE March 19-20, 2019 Jacksonville, Florida April 15-16, 2019 Troy, Michigan

FEES List:

$1,415 $1,274

Members:

TWO-DAYS/1.3 CEUS

Get the complete course description and register: sae.org/learn/content/c1733/

FIND OUT HOW TO GET THIS COURSE DELIVERED TO YOUR LOCATION. CONTACT SAE CORPORATE LEARNING SOLUTIONS. +1.724.772.8529 Visit sae.org/learn/ and select CORPORATE LEARNING

NEW! FUEL SYSTEMS: MATERIAL SELECTION AND COMPATIBILITY WITH ALTERNATIVE FUELS

The introduction of new fuels is of concern to infrastructure and the vehicle industries and the discussion of compatibility timely, given the push toward renewable fuels.

This course introduces you to the factors governing fuel-material compatibility and methods to predict and empirically determine compatibility for new alternative fuel chemistries. By understanding the mechanisms and factors associated with chemically-induced degradation, you will be able to assess the impact of fuel chemistry to infrastructure components, including those associated with vehicle fuel systems. This course looks at compatibility from a fuel chemistry perspective, especially new fuel types such as alcohols and other biofuels. Since most fuels, especially those used in transportation, do not contain appreciable quantities of corrosive acids or water, more emphasis is placed on elastomers and plastics used as seals and structural components. However, discussion of metal corrosion will be included for completeness. The course includes the use of solubility analysis to predict compatibility performance of selected polymer materials and conditions precipitating metal-based corrosion. Empirical results and field observations are presented and discussed in the context of fuel chemistry and material structure. • Select and perform proper compatibility measurements to determine fuel compatibility with materials used in fuel systems • Perform first order solubility analyses to predict incompatibilities • Identify potential infrastructure risks associated with the introduction of new fuels • Recognize and identify conditions which promote corrosion • Select materials that are compatible for a given fuel chemistry WHO SHOULD ATTEND Managers, engineers (mechanical, chemical, materials), systems engineers and designers, and fuel specialists who work for vehicle manufacturers and suppliers, manufacturers of fuel storage, dispensing, and delivery systems, state and federal regulators, fuel additive companies, biofuel producers, and petroleum producers will find this course valuable. LEARNING OBJECTIVES By attending this seminar, you will be able to:

CONTENT HIGHLIGHTS • Expanding Biofuels and Alternative Fuel Use • Government policies influencing fuel use: North America, Europe, Asia • Resource driven alternative fuel use (bio- oil and otherwise) • Global trends • Real world examples of fuel-material incompatibilities • Alternative fuels vs. petroleum-based compositions • Fuels and Fuel Chemistry • Fuel System Materials and Components • Relevant properties • Legacy and new materials and components • Regulations: EPA, State • UL listing standards • Composition and Fundamentals of Polymer and Metal Structures • Plastics - permeation barriers, high density polyethylene, Teflon, flexible plastics and rigid plastic resins • Elastomers – fluorocarbon, nitrile rubber, silicone, polyurethane, neoprene, etc. • Metals – mild and stainless steels, aluminum, nickel, bronze and brass alloys • Definition of Compatibility • Polymers and sealants • Metals • Methodology: Properties and Methods used to Assess Material-Fuel Compatibility • Test fuels (SAE J1681, ASTM, etc.) • Bench Tests: Polymers and Sealants (SAE J1681, ASTM, etc.) • Bench Tests: Metals and Alloys (ASTM, etc.) • Solubility and its Impact on Polymer Compatibility • Use of Hansen solubility parameter methods to predict solubility • Exercises to predict compatibility for selected polymers • Conditions Exacerbating Corrosion • Galvanic • Microbial induced corrosion INSTRUCTOR Michael Kass Fuel, Engines, and Emissions, Oak Ridge National Laboratory

I.D.# C1805

SCHEDULE April 2-3, 2019 Jacksonville, Florida

FEES List:

$1,415 $1,274

Members:

TWO-DAYS/1.3 CEUS

Get the complete course description and register: sae.org/learn/content/c1805/

FIND OUT HOW TO GET THIS COURSE DELIVERED TO YOUR LOCATION. CONTACT SAE CORPORATE LEARNING SOLUTIONS. +1.724.772.8529 Visit sae.org/learn/ and select CORPORATE LEARNING

AUTOMOTIVE PLASTICS: PRINCIPLES OF MATERIALS AND PROCESS SELECTION

Using plastics can be simple, but there is much more behind producing high performance plastic parts.

Plastic - any class of synthetically-produced organic compounds capable of being molded and hardened into a specific shape or form. This course is designed to oer a basic understanding of plastics and plastic processing. This seminar will walk you through the molding process, provide a comprehensive look at the variables in the manufacturing mix, and review characteristics of typical automotive plastics such as PP, PVC, ABS, and more. This seminar will also cover troubleshooting molding mistakes and alternative processes, and review the selection of an application’s appropriate plastic material. Material presented is both an excellent foundation for further development and an extensive update for those already working in the field. LEARNING OBJECTIVES By attending this seminar, you will be able to: • Demonstrate an understanding of typical automotive plastics and primary and application- specific plastics processing methods • Recognize key plastics terminology and parameters related to plastics

I.D.# C0135

SCHEDULE June 10-11, 2019 Troy, Michigan

FEES List:

$1,415 $1,274

Members:

TWO-DAYS/1.3 CEUS

Get more information and register: sae.org/learn/content/c0135/

TRAIN YOUR WHOLE TEAM. CONTACT SAE CORPORATE LEARNING SOLUTIONS. +1.724.772.8529 Visit sae.org/learn/ and select CORPORATE LEARNING

• Explain alternative molding processes • Prevent or reduce molding mistakes • Understand the molding cycle • Troubleshoot the processing operation

WHO SHOULD ATTEND This seminar is designed for those who are new to automotive plastics, as well as those who have some experience. The program will benefit product designers, process engineers, purchasing agents, project engineers, manufacturing engineers, material engineers, and sales and marketing professionals.

CONTENT HIGHLIGHTS • Introduction to Injection Molding • The Injection Molding Machine • The Molding Cycle • Typical Injection Molding Mistakes • Mold(s) • Function

INSTRUCTOR Robert G. Speirs Associate Professor of Plastics Programs, Ferris State University

BRAKE FRICTION MATERIALS: TESTING, QUALITY AND SELECTION

This seminar will provide an introduction to brake lining

The choice of brake friction materials varies per application, but each must have the appropriate coe°cient of friction and be able to disperse large amounts of heat without adversely eecting braking performance. This seminar will provide an introduction to brake lining raw materials and formulation, manufacturing, quality control and testing. The course covers the critical elements that must be reviewed before arriving at a lining selection decision. Dierent classes of friction material and their use will be defined. LEARNING OBJECTIVES By attending this seminar, you will be able to: • Describe the principles of friction • Define the basic elements of friction material formulations • Identify the dierence between OE and after-market friction materials • Identify appropriate tests to distinguish the dierences between friction materials • Interpret friction material test results WHO SHOULD ATTEND Brake system designers, quality control auditors, product development engineers, application engineers, lab/bench/vehicle test technicians, managers/friction material sales and marketing will all gain valuable insight into this highly guarded industry. CONTENT HIGHLIGHTS • Principles of Friction Materials • Lining Coe°cient of Friction • Formulation/Compounding Friction Material • Manufacturing Friction Material • General Asbestos/Non-asbestos Friction Material Characteristics • Friction Material Testing • Edge Code • Bench & Vehicle Tests • Wheel Dust Test • Government Regulations • OE and After-market Friction Material Lining Selection • Issues Facing Friction Material Industries • Workshop INSTRUCTOR

raw materials and formulation, manufacturing, quality control and testing. The course covers the critical elements that must be reviewed before arriving at a lining selection decision.

I.D.# C1020

SCHEDULE Future offerings are being scheduled for this course. Check the course web page for the most up-to-date schedule and information.

FEES List:

$835 $752

Members:

ONE-DAY/.65 CEUS

Get more information and register: sae.org/learn/content/c1020/

Mohammad Vakili Industry Consultant

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