Automotive Composites Technology Engineering Academy     


I.D.# ACAD08Printable Description
Duration: 5 Days
November 10-14, 2014 (8:00 a.m. - 5:00 p.m. ) - Troy, Michigan  

Hotel & Travel Information

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.


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.

Topical Outline

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

Composites Overview - Dr. Pipes

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
Carbon Fiber and the Obstacles to Automotive Industry Implementation - Dr. Warren
  • Cost effectiveness of Current Carbon Fiber Components
  • Carbon Fiber Manufacturing
  • Carbon Fiber Cost Drivers
  • Routes to Lower Cost Carbon Fiber
  • Other Obstacles for more Wide Spread use of Carbon Fiber Composites in the Automotive Industry
Composite Materials: Fibers and Polymers - Dr. Siavoshani
  • 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

Introduction to Composites Manufacturing - Dr. Siavoshani

  • Prepreg technology
  • Infusion molding-RTM, VARTM
  • Compression molding
  • Pultrusion
  • Injection molding LFT
Performance of Composite Materials - Dr. Pipes
  • Elasticity of Anisotropic Materials
  • Analysis of Discontinuous Fiber Composites
  • Analysis of a Continuous Fibetr Lamina
  • Effective Elastic Moduli
  • Elastic Analysis of Composite Laminates
  • Strength Criteria for Homogeneous Composites
  • Dehomogenization for Micro-Strength
  • Interlaminar Fracture
  • Free-Edge Effects
Composite 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
  • Coefficients of thermal expansion
  • Laminate strength and modulus
  • Open-hole tensile strength
  • Mode I and Mode II fracture toughness
Composite Computer Simulation Software Demonstrations

A series of technical simulation presentations by various companies will be presented which will link the simulation technologies to the design, development, manufacturing, and engineering performance and analysis.

  • Dassault Systemes
  • Vistagy Siemens
  • SAMTECH Siemens
  • ESI
  • MSC Digimat
  • Autodesk
  • Altair
  • Moldex 3D
Non-destructive Inspection and Evaluation of Composite Materials and Structures - Dr. Adams
  • Common composite material damage mechanisms
  • Non-destructive measurements and their sensitivities to common damage mechanisms
  • Material health monitoring and prognostic measurements
  • Nondestructive inspection technologies
  • Case studies of nondestructive inspection methods
  • Interactive real time demonstrations of inspection methods
Durability - Dr. Mallick
  • Fatigue durability
  • Designing against fatigue
  • Crash durability
  • Designing against crash
Joining Technology - Dr. Mallick
  • Mechanical joining for composites - fasteners, design, strength
  • Adhesive joining - adhesives, analysis and design
  • Joining with metals - special considerations

Structural Composites - The Analysis Challenge from an Industry Perspective

Crush, Damage and Modeling of Structural Energy Absorption - Dr. Shahwan
  • Energy management and the concept of energy absorption/dissipation
  • Major distinctions between energy absorption mechanisms
  • Modes of damage initiation and progression in fiber-reinforced polymeric composites
  • Computational considerations: simulation is not prediction, and correlation is not causation
  • Limitations and ranges of applicability (why current CAE tools have limited predictive power)
  • Phenomenological and physics-based models
  • Discretization, localization, homogenization and representative equivalency
  • Limitations of common averaging and homogenization techniques
  • Material scale, model scale, physical scale and size effects on nominal strength
Challenges, Future Analysis Trends, and Demonstration Cases - Dr. Shahwan
  • The overall analysis challenge is evolutionary, with increasing complexity during integration
  • What are the barriers preventing robust & accurate modeling of advanced materials
  • Verification & validation of new modeling methodologies - benchmarking & standardization
  • Analysis using in-situ properties vs. estimated/presumed averaged (bulk) properties
  • Modeling the manufacturing process, in-service/environmental effects & long-term performance)
  • Damage repairability, repair technologies and the lurking challenges
  • Integrated Computational Materials Engineering (ICME) - the emerging need
  • The hierarchical (sequential) analysis ("modeling the input") - an emerging paradigm shift
  • Automotive model for pre-competitive collaboration on advanced high-risk research
  • The 25-year old Automotive Composites Consortium (ACC); USCAR and the US-DoE
  • ACC's energy management and modeling projects: portfolio of advancements
  • ACC's demonstration projects
Processing of Composite Materials - Dr. Hubert
  • 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
Lessons Learned in the Composites Academy - Dr. Siavoshani
  • Summary of lessons learned
  • Framework for future progress

Instructor(s): R. Byron Pipes, Saeed Siavoshani, Doug Adams, Pascal Hubert, Pankaj K. Mallick, Khaled Shahwan, Dave Warren

R. Byron Pipes - Co-Lead InstructorByron Pipes
Dr. Pipes is the John L. Bray Distinguished Professor of Engineering at Purdue University and has been a member of the National Academy of Engineering since 1987. His prestigious academic career includes service as President of Rensselaer Polytechnic Institute and Director of the Center for Composite Materials at the University of Delaware. In his early career, he worked in composites development for General Dynamics Fort Worth (now Lockheed.) Dr. Pipes is an international expert recognized for his outstanding scholarship in the field of polymer composite materials in the areas of advanced manufacturing science, durability, design and characterization and for his leadership in creating partnerships for university research with the private sector, government and academia. He is the author of over one-hundred archival publications including four books and has served on the editorial boards of four journals in his field. He holds Fellow rank in ASC, ASME and SAMPE and is a registered professional engineer in the State of Delaware. Dr. Pipes received a Ph.D. in Mechanical Engineering from the University of Texas at Arlington and a M.S.E. from Princeton University.

Saeed Siavoshani - Co-Lead InstructorSaeed Siavoshani
Dr. Saeed J. Siavoshani is currently a Technical Program Manager for LMS, A Siemens Company and an adjunct professor at the University of Detroit Mercy where he teaches a comprehensive electric vehicle course. In addition Dr. Siavoshani serves as the Chief Industry Advisor for SAE Professional Development Seminars and Academies. Over the past two decades, he has worked for the Dow Chemical company, General Motors Corporation and Ford Motor Company as an NVH technical specialist. During his career, Dr. Siavoshani has also worked on composite projects related to offshore oil and gas, infrastructures, and pressure vessels and automotive systems including powertrain, body structure, exhaust/induction systems as well as the interior and exterior of the vehicle. He has also been instrumental in the development of new technology, notably the integrated Front of Dashboard concept and Acoustomize, a unique method of analyzing and offering solutions to automotive noise problems. He has also worked in the area of thermoforming utilizing electro-magnetic field technology. Dr. Siavoshani has helped to build the infrastructure for the electric vehicle battery pack including thermal management as well as reducing the weight of the overall battery. He has been granted several patents and was presented the SAE Forest R. McFarland Award in 2012 for distinction in professional development and education. Dr. Siavoshani has a M.S. in Mechanical Engineering from Wayne State University and a Ph.D. in Mechanical Engineering from Oakland University.

Doug Adams Doug Adams
Dr. Adams is Distinguished Professor and Chair of Civil & Environmental Engineering at Vanderbilt University where he directs the Vanderbilt Laboratory for Systems Integrity & Reliability which houses advanced instrumentation including three-dimensional laser vibrometer and Digital Image Correlation systems for characterizing composite material behavior. He and his students use nonlinear structural dynamic model identification techniques and multi-physics measurements to illuminate the complex ways in which materials and machines degrade in order to prevent failure. He has published 72 archival journal papers, 154 conference papers, several book chapters, and a textbook on structural health monitoring, and he has graduated 43 MS and PhD students. His work has generated 13 patents including several technologies in the area of composite material inspection and integrated health monitoring, and he is actively implementing this technology with industry to more effectively manage the reliability of aircraft, ground vehicles, and power systems and reduce operation & maintenance costs. Dr. Adams has secured 93 federal and industrial contracts/grants and has received a number of awards including the Presidential Early Career Award for Scientists and Engineers and the DiMichele Award from the Society of Experimental Mechanics. He has delivered over 200 talks worldwide including keynote addresses in the United States and Europe. He is a winner of numerous teaching awards and his name is recorded in the Book of Great Teachers at his former institution, Purdue University. He was named a Fellow of ASME in 2011 and is Managing Editor of the International Journal of Structural Health Monitoring.

Pascal HubertPascal Hubert
Dr. Hubert is currently an Associate Professor at McGill University where he specializes in computational and experimental mechanics and processing for composite materials. Prior to joining the university, he was the owner of Composites Innovation Inc.,served as a Visiting Scientist as NASA Langley Research Center and worked in industry for Forintek Canada Corporation and Bombardier Inc. Dr. Hubert received his B.S in Mechanical Engineering and M.ScA in Composites Materials from the Universite de Montreal and his Ph.D in Composites Materials from the University of British Columbia.

Pankaj K. MallickP.K. Mallick
P. K. Mallick is the William E. Stirton Professor of Mechanical Engineering and the Director of the Interdisciplinary Engineering Programs at the University of Michigan-Dearborn. He is also the director of the Center for Lightweighting Automotive Materials and Processing at the university. Dr. Mallick worked in industry for several years before joining the university where his principal research areas are mechanical properties, design characteristics, joining and processing of polymers, fiber reinforced composites and lightweight automotive materials. He has authored or co-authored three books on fiber reinforced composites, including Fiber Reinforced Composites: Materials, Manufacturing and Design and Materials, Manufacturing and Design for Lightweight Vehicles. Dr. Mallick is the recipient of the Distinguished Faculty Research Award from the university and the Distinguished Faculty Award from the Michigan Association of Governing Board of State Universities and is a Fellow of the American Society of Mechanical Engineers. He received his Ph.D. from the Illinois Institute of Technology.

Khaled ShahwanKhaled Shahwan
Dr. Shahwan is a world recognized expert and an industry leader in state-of-the-art virtual methodologies and engineering for advanced lightweight composites and automotive safety technologies. He is a member of the Board of Directors of the Automotive Composites Consortium (ACC) - a division of the U.S. Council for Automotive Research (USCAR), where he served as Chairman of the Board in 2011. He has held several expanding roles within the ACC leadership including the Chairman of the Predictive Technology Development and Composites Crash Energy Management Group. Dr. Shahwan is a leading member of several industry-government collaborative programs (USAMP, USDRIVE), and has initiated and managed several long-term collaborative R&D and innovation projects between the OEMs, suppliers, leading academic institutions and U.S. Dept. of Energy. At the Chrysler Technology Center Dr. Shahwan is a leading specialist in light-weighting and advanced computational methodologies as well as passive and active safety technologies. Prior to joining Chrysler, Dr. Shahwan worked for several years at Ford Research Labs and Ford's Advanced Engineering. Earlier in his career he held senior consulting and research positions in industry and at the University of Michigan-Ann Arbor. Dr. Shahwan is a member of the Editorial Boards of the Journal of Engineering Mechanics, Int. J. of Vehicle Safety, Int. J. of Vehicle Design, Advances in Materials Science and Engineering, and Int. J. of Automotive Composites. He is an elected Associate Fellow of the American Institute of Aeronautics and Astronautics (AIAA), and has over 40 peer-reviewed journal publications, conference presentations, and over 40 corporate and industry-government collaboration reports. Dr. Shahwan received several recognitions including the 2013 Rising Engineering Star by Design News, USCAR's Special Recognition Award for Outstanding Contributions, as well as the Executive & Team Leadership (Technology Innovation) Award by the Society of Plastics Engineers (SPE). Dr. Shahwan serves on the Advisory Board of SFSU's School of Engineering. Dr. Shahwan holds a Ph.D. and an M.S. in Aerospace Engineering, and an M.S. in Civil/Structural Engineering from the University of Michigan-Ann Arbor, and a B.S. in Civil Engineering from SFSU.

Dave WarrenDave Warren
Dr. Warren is currently the Program Manager for the Transportation Materials Program at Oak Ridge National Laboratory (ORNL) and Field Technical Manager for Materials in the Lightweighting Materials sub-program of DOE Vehicle Technologies where his focus is on materials science technologies related to carbon fiber, carbon fiber composites, glass fiber composites, magnesium, aluminum, titanium, and high strength steels. Prior to joining ORNL, he served as Program Manager for Peacekeeper ICBM propulsion, Small ICBM basing and Rail Garrison support as a Captain in the United States Air Force. He has numerous technical publications focused mainly on composite materials development and application and has chaired international conferences and sessions and given plenary or keynote addresses. His membership on boards and steering committees includes: USDRIVE Materials Tech Team; U.S. Automotive Materials Partnership; Georgia Technological University - Materials Science Department Review Board; University of Alabama - Birmingham - GATE Materials Science Advisory Board. Dave completed undergraduate and graduate work in materials science and engineering at Vanderbilt University.

Fees: $3345.00 ; SAE Members: $2676.00 - $3011.00

3.8 CEUs
You must complete all course contact hours and successfully pass the learning assessment to obtain CEUs.

To register, click Register button at the top of this page and submit the online form, or contact SAE Customer Service at 1-877-606-7323 (724/776-4970 outside the U.S. and Canada) or at