Lasers in Engineered Welded Blanks Shiloh Industries, Inc.

Shiloh Industries, Inc.

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Company Overview • • • • • •

Established in1950 1,200 employees Publicly traded as “SHLO” on NASDAQ Exchange FY 2011 Sales - $518 million TS16949 approved – All Plants 9 operations in United States & Mexico

Shiloh Capabilities Include: • Tool & Die Development • Coil Processing • Precision Blanking • Engineered Welded Blanks • Complex Stamping & Modular Assemblies • Deep Draw Capabilities • AcroStikTM Laminate Solutions Shiloh Industries, Inc.

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Geographic Locations Medina Blanking OH, USA

Liverpool Coil Processing OH, USA

Canton Manufacturing; Sales & Technical Center, MI, USA Engineering, Blanking, EWB, Laser Cutting Engineering, Blanking, EWB, Stamping, Modular Assembly

Coil processing (slitting & CTL), Stamping, Modular Assembly,

AcroStikTM

Wellington Manufacturing OH, USA

Ohio Welded Blank OH, USA

Complex Stamping, Modular Assembly

Blanking, EWB, AcroStikTM

Bowling Green Manufacturing KY, USA

Jefferson Manufacturing GA, USA

Dickson Manufacturing TN, USA

Heavy Gauge Blanking, Stamping

Blanking, EWB, Stamping

Complex Stamping, Modular Assembly

Shiloh de Mexico Ramos Arizpe, Mexico

Blanking, EWB, Stamping, Modular Assembly

Shiloh Industries, Inc.

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Product Applications

Shiloh Industries, Inc.

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First Operation Blanking

Shiloh Industries, Inc.

First Operation Blanking

Shiloh Industries, Inc.

Laser Process Capabilities Engineered Welded Blanks (EWB) Engineered Welded Blanks are more advanced laser welded blanks, manufactured from two or more blanks of the same or different steel grades or gauges welded together. A high level of engineering analysis and laser technology is applied to achieve a reduction in vehicle mass, number of parts, and tooling cost, while improving body strength. It is important to note, that unlike other welding applications, a welded blank will be formed after welding. The stresses applied during the forming process require a very high quality weld placed in the exact location to optimize mass and material utilization.

Shiloh Industries, Inc.

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Why do we use Engineered Welded Blanks? Different gauges, materials & coatings can be incorporated into one blank  Blank can be engineered to desired properties

Consolidation of components  Reduction in number of parts  Reduced tooling costs  Reduced assembly operations and equipment

Material utilization  Reduction in engineered scrap due to improved blank nesting

Mass reduction on vehicle Shiloh Industries, Inc.

Shiloh EWB History Engineered Welded Blank Capabilities • Started Engineered Welded Blank production in 1989 • First welded blank was mash seam welded • Reclamation of offal from large body blanks

• Moved to laser welding in 1994 • Current production est. 10,000,000 EWB/yr • 5 EWB facilities currently

Shiloh Industries, Inc.

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Linear Welded Components

Underbody Components

Door Inners Body Side Inners

Shiloh Industries, Inc.

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Multi-Linear Welded Components

Rear Door Inner (Draw)

Rear Door Inner (Final)

Body Side Inner Shiloh Industries, Inc.

Lift Gate Inner 11

Curvilinear Welded Components

Shiloh Industries, Inc.

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Advantages of Laser Welding • Improved speed and flexibility • Common systems with interchangeable fixtures

• Improved weld quality • Smaller HAZ • Reduced work piece distortion

• Improved formability • Better material utilization • No overlap or flange required • One side access • Enhanced capabilities for curvilinear welding

Shiloh Industries, Inc.

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Applications • Material Optimization – Reduction in Engineered Scrap Current Design 1727 mm 68.750”

Total Material usage = 32.66 kg

63.843” 1600 mm

Three Piece Even gage EWB Design

Total Material usage = 26.33 kg

Advantages  6.33 kg material savings per part  Blank A and B can be uncoated Shiloh Industries, Inc.

Applications • Part Consolidation Blank A,

2 Pc. Baseline Design

EWB Option

Material Usage 5.23 kg

Material Usage 4.38 kg

On Vehicle Mass 2.74 kg

On Vehicle Mass 2.38 kg Blank B,

Advantages • 0.84 kg of Material savings per side Reinforcement

• 0.36 kg of mass savings on vehicle per side • Lower stamping die cost

Pillar ,

• No welding or fixture costs • Lower press time, transportation, inventory

Shiloh Industries, Inc.

Balance - Formability & Mass Savings

Thinning

Blank

Vehicle mass optimization example: For some applications the part geometry requires a high level of material elongation for forming. Placement of the weld seam is critical. This example shows a solution to achieve acceptable levels of material thinning by correct placement of the weld line and mass optimization with curvilinear laser weld.

40 %

Shiloh Industries, Inc.

30 %

15 %

15 %

Applications • Vehicle Mass Optimization Base Design

Blank

Curvilinear Weld Option

Mass in kg

Thick

Blue

4.75

Thin

Green

4.59 Total

Shiloh Industries, Inc.

9.34

Blank

-1.1 Kg /Door Mass Savings

Mass in kg

Thick

Pink

2.75

Thin

Brown

5.48

Total

8.23

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Applications • Lightweight Opportunities Lift gate Inner and Reinforcements

4-Pc Curvilinear EWB Proposal Blank A

Blank B

Blank C

Blank D

Advantages • Eliminates 4 parts, 2 stamping dies and 1 blank die • Steel Savings of 5.45 kg. • Mass savings of 0.90 kg on vehicle

Shiloh Industries, Inc.

Laser Welding Keys to Success • • • • •

Training Laser Champion(s) Inventory of key maintenance items Quality fit up of components Good fixture design

Shiloh Industries, Inc.

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Future Applications • Laser Welding of Advanced materials • AHHS coated & uncoated • PHS coated & uncoated – Laser Removal (ablation) of coatings

• Aluminum • Fiber reinforced Plastics

• Laser Welded Coils • Highly Engineered Welded Blanks • EWB with addition of Acoustic/structural patches

• Heavy Gage Frame (class 8 trucks)

Shiloh Industries, Inc.

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Shiloh Industries, Inc.

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