Mar 25, 2019 8:15 pm

Stamping and Assembly of Tesla Model 3

By |2019-02-26T20:14:21-04:00Mar 25, 2019|Blog|0 Comments

Only 35 high end Schuler servo stamping presses exist in auto manufacturing worldwide and the one at Tesla is the first one in the US. The equipment has allowed Tesla to form unique parts, like the Model 3 front fender, which engineers say has greater depth in a single piece of stamped steel than any other fender in production. Tesla chose to build a factory to handle all of its [...]

Mar 18, 2019 6:54 pm

Different Skills Needed For Many Manufacturing Jobs

By |2019-03-11T19:12:51-04:00Mar 18, 2019|Blog|0 Comments

A forecast from The World Economic Forum states globally, 75 million manufacturing-related job losses are expected by 2022, but there will be 133 million new jobs available to those with proper skills. 54% of employees at large companies need significant re-training and up-skilling for these jobs. Urgent challenges for businesses and policymakers include providing reskilling opportunities, enabling remote work and building safety nets to protect at-risk workers and communities. Read [...]

Mar 11, 2019 7:41 pm

Differences Between Aluminium Alloys

By |2019-03-02T19:47:46-04:00Mar 11, 2019|Blog|0 Comments

5XXX and 6XXX sheet aluminum alloys may be produced from proprietary alloy compositions. Each family shares similar characteristics, but each alloy retains unique features. For example, AA6022 has the strength of AA6111 and the formability of AA6016A, but may be more costly since the low copper and low iron requirements make it difficult to produce from recycled stock. Certain alloys may be available only from specific companies, and may be [...]

Mar 4, 2019 6:52 am

​2019 Chevy Silverado – Parts Labeled with Grade and Strength

By |2019-02-25T19:03:07-04:00Mar 4, 2019|Blog|0 Comments

A slideshow of photos taken at I-CAR’s booth at SEMA 2018 is at the bottom of an article containing information about AHSS content in 2019/2020 vehicles. These photos highlight sections of the 2019 Silverado body, showing several parts labeled with strength levels and grade. You can see several 780MPa and 980MPa steel parts, as well as some UHSS parts. GMs strategy on their new truck is to use 6XXX aluminum [...]

Feb 28, 2019 9:50 am

Tooling Wear When Forming Stainless and Aluminum

By |2019-02-25T19:58:38-04:00Feb 28, 2019|Blog|0 Comments

I always read what Pete Ulintz writes. His September 2018 article in Metalforming Magazine discusses tooling wear when forming stainless and aluminum. A few additional comments from my experience: A) Your metal supplier may be able to provide you coils with the PE/PVC coating already applied. B) You might need to adjust your forming approach. I've worked with parts where the polymer coating was ripped off when going through the [...]

Feb 22, 2019 9:59 am

​Why iPhones Won’t Be Made in U.S.A.

By |2019-02-21T21:06:32-04:00Feb 22, 2019|Blog|0 Comments

​High volume low margin production goes to low cost countries. Equipment and skills available in US transition to higher margin value-added production. Even if manufacturers want to move production back to the US, investment in automation and appropriate talent is needed - and that's not necessarily quick to pull off. Dr. Susan Helper, an econ prof at Case Western, says that ​Apple can make more products in the US by [...]

Feb 7, 2019 7:34 pm

​1300MPa Cold Stamped Steel at Mazda

By |2019-02-04T20:02:31-04:00Feb 7, 2019|Blog|0 Comments

NSSMC (Nippon-Sumitomo) and JFE Steel jointly developed a cold formable steel having a minimum tensile strength of 1300MPa. The first production application is the 2019 Mazda 3, where it is used for the front pillar inner, roof rail inner, hinge pillar reinforcement, roof rail reinforcement, side sill inner reinforcement, and the No. 2 crossmember.  Mazda expects to use this throughout their lineup.  No doubt that joining and repair techniques need [...]

Jan 26, 2019 8:13 pm

​SpaceX to Build Starship Rocket out of 3XX Stainless Steel, Not Carbon Fiber

By |2019-01-24T20:28:04-04:00Jan 26, 2019|Blog|0 Comments

​Stainless steel will be used for the SpaceX Starship and Super Heavy rocket booster. Over the spectrum of operating temperatures and ​conditions encountered, stainless steel has better performance than carbon fiber. ​From a recent interview with @PopMech, it's apparent that @ElonMusk has more than just a passing awareness of materials and manufacturing. In it, Musk describes how material selection affects stiffness, fracture toughness, and of course cost. He talks about [...]

Jan 18, 2019 9:02 pm

Efficiency at What Cost?

By |2019-01-14T21:10:20-04:00Jan 18, 2019|Blog|0 Comments

Electric motor efficiency is improved by using thinner sheets of electrical steels. This is important to meet the needs of hybrid/electric vehicles. But more laminations need to be stamped from this thinner metal to get to the same stator height. An article from steelmaker voestalpine says that at least 60 additional high-precision stamping lines/presses will be needed by 2025 for production of 25 million drive motors with a lamination thickness [...]

Jan 14, 2019 10:28 pm

POSCO will invest US$40 billion and hire 20,000 by 2023

By |2019-01-10T22:53:01-04:00Jan 14, 2019|Blog|0 Comments

​More than half will go to automating a 3.52 million ton Gwangyang Steel Mill blast furnace, expanding production capability of their "Giga Steel" and establishing power generation facilities using byproduct gases. Other funds will be devoted to secondary battery materials and upgrading lithium-extracting technologies, with a similar amount going to their energy and infrastructure businesses. Read more about Posco's plan. -Danny Schaeffler, and ​