Metal Matters Columnist, MetalForming Magazine, Precision Metalforming Association (PMA):
November 2023
Use Lean Six Sigma for Efficiency & Quality Improvement
October 2023
Seeking Small Victories: Continuous Process Improvement
September 2023
Be Wise: Ask the “Five Whys” & Create a Fishbone for Faster Problem Solving
August 2023
An Introduction to Quality Management Systems
June/July 2023
Hydroforming
May 2023
Alloy-Property Variability Belongs in Your Workforce-Development Plans
April 2023
Save Time, Money, and Weight with Tailored Parts
March 2023
Metal Properties: R-Value
Jan/Feb 2023
Talkin’ Bout My Generation: Steel Grade Development Over Time
January 2023
Metal Properties: N-Value
December 2022
Metal Properties: Uniform Elongation
November 2022
Metal Properties: Total Elongation
October 2022
Metal Properties: Tensile Strength
September 2022
Metal Properties: Yield Strength
August 2022
Metal Properties: Elastic Modulus
June/July 2022
Decarbonization of Sheet Steel and Aluminum
May 2022
Crystallography 101
April 2022
Brinell, Rockwell and Vickers Hardness Testing: Use and Misuse
March 2022
Strength and Stiffness are Not The Same
February 2022
Edge Cracking in Advanced Steels
January 2022
New Metal Matters Column Tackles Pressroom Challenges
Science of Forming Columnist, MetalForming Magazine, published by Precision Metalforming Association (PMA):
December 2021
Don’t Blindly Use The 20% Maximum Thinning “Rule”
November 2021
Opportunities Outweigh Apprehension When Forming New Metal Alloys
October 2021
Advanced High Strength Steel Application Guidelines: Online, Expanded and Updated
September 2021
What A Drag It Is Getting Old: Aging Inventory Turns Value-Added Stampings into Scrap
August 2021
The Ethics of Data Falsification
July 2021
Work Hardening is Your Enemy
June/July 2021
Work Hardening is Your Friend
May 2021
Approach Stamping Problems Like a Crime Scene Investigator
April 2021
Gemba Walks: In Battle of Theory vs. Reality, Reality Always Wins
March 2021
Troubleshooting Sheet Metal Forming Problems, Part 2: The Stamping Process
February 2021
Strong Choices Expand High Strength Options
January 2021
Troubleshooting Sheet Metal Forming Problems, Part 1: The Sheet Metal
December 2020
A Brief History of Formable High-Strength Steels, Part 2: Advanced High Strength Steels
November 2020
Loose Change Management Can Be Costly
October 2020
A Brief History of Formable High-Strength Steels, Part 1: HSLA and Bake-Hardenable Steels
September 2020
A Brief History of Steelmaking
August 2020
Limitations of Hardness Testing for Deep Drawing Applications
June/July 2020
Tensile Testing Part 2: Terminology
May 2020
Tensile Testing Part 1: Equipment, Samples, and Procedures
April 2020
Coming Soon: AHSS Application Guidelines, Online and Updated
March 2020
Don’t Forget About the Surface
February 2020
Getting More Than You Ordered
January 2020
Material Selection: The Rest of the Story
December 2019
Specifying and Using Hot-Dip Galvanized, Galvannealed and Electrogalvanized Steel
November 2019
Zinc-Coated Steels–Part 1: Electrogalvanizing, Hot-Dip Galvanizing and Galvannealing
October 2019
Differences Between Tryout and Production Conditions
September 2019
Growing Your Business: Know How Your Customer Uses Your Product
August 2019
A Successful Stamped-Product Launch: Know What Goes Into Your Tooling
July 2019 2019
Intro to Strain Analysis: Techniques to Promote Measurement Accuracy
June 2019
Intro to Strain Analysis: Evaluating the Impact of Allowed Tensile-Property Variation
May 2019
Introduction to Strain Analysis: Generating the Thinning Limit Curve from the Forming Limit Curve
April 2019
Introduction to Strain Analysis: The Forming Limit Curve
March 2019
Introduction to Strain Analysis: Measuring Strains
February 2019
The Importance of Tensile Test Standards and Gauge Length
January 2019
Beyond the TYE: uniform elongation and n-value
December 2018
Sims aren’t everything
November 2018
We’ve come a long way, baby–30 years of metals
October 2018
Use reference panels when troubleshooting forming problems
September 2018
Steel terminology part 1: better forming grades
August 2018
Golf Shots and Manufacturing Variability
July 2018
You Get What You Order: Know the Details in the Specifications
June 2018
Introduction To Stainless Steels For Stamping Applications
May 2018
The Aluminum-Steel Battle In Automotive Applications
April 2018
Know Your Sheetmetal–Aluminum-Alloy Terminology
March 2018
Know Your Sheetmetal Terminology–Part 2
February 2018
Know Your Sheetmetal Terminology–Part 1
January 2018
Seeing Into The Future By Looking Into The Past
December 2017
The More You Know
Columnist, Stamping Journal and www.TheFabricator.com, published by Fabricators and Manufacturers Association (FMA):
November 2017
The importance of local formability
September 2017
Hardness tests measure indentation resistance, not sheet steel formability
July 2017
An overview of austenitic and ferritic stainless steels
May 2017
Troubleshooting stamping performance
March 2017
A short study on sheet steel specification syntax, Part I
January 2017
Achieving successful stamping of AHSS
October 2016
Stretch flanging and hole expansion with AHSS
September 2016
Grade designations for sheet metals
August 2016
A review of steel microstructures
May 2016
Getting to know more about the metal you are forming
March 2016
Troubleshooting sheet metal defects: Part II
January 2016
Troubleshooting sheet metal defects: Part I
December 2015
The differences between stiffness and strength in metal
September 2015
Sheet aluminum alloys for cans and cars
July 2015
A closer look at low-carbon sheet steels
May 2015
The unique characteristics of dual-phase steels
March 2015
WorldAutoSteel Guidelines for AHSS shed light on lightweighting
June 2010
Understanding steelmaking for better forming… and forming better supplier-user partnerships for profitability
January 2008
Stamping 101: Material guidelines – Properties and Characteristics that Affect Formability
September 2005
Introduction to advanced high-strength steels – Part II: Processing considerations
August 2005
Introduction to advanced high-strength steels – Part I: Grade overview
November 2004
Advanced high-strength steels: Enhanced formability adds to vehicle strength
Founding Columnist, Tool & Die Authority Newsletter, published by Precision Metalforming Association (PMA):
July 2010
Hot Dipped Galvannealed Steels (or, I Zinc We Need Corrosion Protection and Weldability)
June 2010
Continuous Hot-Dipped Galvanizing of Sheet Steels (or, I Zinc We Need Some Corrosion Protection)
May 2010
Problem-Solving Techniques: The Five-Whys (or, How to be a Wise Guy)
April 2010
Specimen Shapes Shown in Sheet-Steel Specifications (or, Know Where the Numbers Come From)
March 2010
Loose Change Management Can Be Costly (or, Poor Record Keeping Can Lead to Costly Actions)
February 2010
What is Steel? Part 4: Dual Phase Steels (or, The Shape of Things to Come)
January 2010
The 20-Percent Maximum Thinning Rule (or, How Much is Too Much?)
December 2009
Root Cause Defect Analysis: Working with Your Supplier (or, It’s Your Problem Even When It’s Not Your Problem)
November 2009
Online Steel Resources (or, Steel Crazy After All These Years)
October 2009
Steel Mills are Heating Up (or, the Law of Unintended Consequences)
September 2009
The Sound of One Hand Clapping (or, Are You Really an Author if No One Reads What You Write?)
August 2009
Limitations of Hardness Testing for Deep-Drawing Applications (or, How to Make a Good Impression)
July 2009
Stronger and Thinner for Summertime (or, Building a Better Body One Part at a Time)
June 2009
Sampling Sheet Surfaces for Successful Stampings (or, Seeing the Forest and the Trees)
May 2009
Troubleshooting Sheetmetal Problems-Part 2(or, If You Always Do What You Always Did, You’ll Always Get What You Always Got)
April 2009
Troubleshooting Sheetmetal Problems (or, Meticulously Mending Metal with Mettle)
March 2009
What is Steel? Part 3: Steel Microstructures and Phases (or, While the Iron is Hot, Grab It!)
February 2009
What is Steel? Part 2: Medium-Strength and Conventional High-Strength Steels (or, Ironing Out the Differences)
January 2009
What is Steel? Part 1 (or, Too Many Irons in the Fire)
December 2008
The Case for Thinning Strain Analysis (or, Strain Spots Keep Falling in the Red)
November 2008
Circle Grid Strain Analysis – Confirm that Ellipse Measurements Make Sense (or, It’s My Destiny to be The King of Strain)
October 2008
Measuring Accurately During Circle Grid Strain Analysis (or, I Can See Clearly Now, The Strain Is Gone)
Publications (Books and Proceedings):
“Risks of Generic Material Card Usage,” (with E. Billur & V. Millioto), Great Designs in Steel, sponsored by American Iron & Steel Institute, May 2024; https://www.steel.org/wp-content/uploads/2024/05/09.45-T2_Schaeffler-Billur-Millioto_Risks-of-Generic-Material-Card-Usage.pdf
“Hot-Stamped Steel and Aluminum Drive Autobody Changes” (with E. Billur), MetalForming Magazine published by PMA, Feb 2024; https://www.metalformingmagazine.com/article/?/end-market/automotive/hot-stamped-steel-and-aluminum-drive-autobody-changes
“Analysis of Sheet Forming Failures,” ASM Handbook, Volume 11A: Analysis and Prevention of Component and Equipment Failures, ASM International, 2021. https://doi.org/10.31399/asm.hb.v11A.a0006801.
“Tensile Tests, Metal Certs and Simulation” and “The Effects of Automotive Lightweight-Initiatives on Die Design Strategy and Construction,” presentations and publication at FABTECH ‘19, Chicago, IL, Sponsored by FMA/SME/PMA/CCAI/AWS, November 2019.
“Friction Coefficient Evaluation on Aluminum Alloy Sheet Metal Using Digital Image Correlation, ” E. Duan, J. Li, D. Schaeffler, H. Wang, L. Yang, SAE Technical Paper 2018-01-1223, 2018, https://doi.org/10.4271/2018-01-1223.
“The Importance of Lubrication in Sheet Metal Selection for Automotive Body Construction,” B. Harwood and D. Schaeffler, Tribology & Lubrication Technology; Vol. 73, Issue 11, (Nov 2017): 48-50. https://www.stle.org/files/TLTArchives/2017/11_November/Afton_Chemical_Corporation.aspx
Sheet Metal Forming – Engineering and Business Management, co-written and co-edited by 4M Partners, LLC, 355 pages, 2010; ISBN 978-0-615-42813-0.
“Troubleshooting Formability Problems Using Strain Analysis,” ASM Handbook, Volume 14B, Metalworking: Sheet Forming, ASM International, 2006. Written with E.J. Vineberg.
“CAD/CAM and Die Face Design in Sheet Metal Forming,” ASM Handbook, Volume 14B, Metalworking: Sheet Forming, ASM International, 2006. Written with E.J. Vineberg and E.A. Herman.
“Forming Higher Strength Steels,” presentation and publication at Metalform ’06, Nashville, TN, Sponsored by Precision Metalforming Association (PMA), March 2006.
“Thinking Outside the Circles: Examples of Novel Sheet Metal Forming Problem Solving”, presentation and publication at Metalform ’06, Nashville, TN, Sponsored by Precision Metalforming Association (PMA), March 2006. Written with E.J. Vineberg.
“Standardizing Dent Resistance Testing Through a Solid Partnership,” Body Engineering Journal (Am. Soc. Body Engineers), Spring 1997, p. 46-48.
“Quasi-Static Dent Resistance Evaluations and Formed Panel Properties of Door Assemblies,” 1996 International Body Engineering Conference, Materials & Body Testing, Section 2.1.3. Written with D.A. Stoddard, and C.D. Horvath.
“Low Carbon P/M Alloy Steels,” 1992 Powder Metallurgy World Congress, MPIF International, NJ. Written with A. Lawley, and R. Causton.
“High Strength Low Carbon Powder Metallurgy Steels: Alloy Development With Transition Metal Additions,” Ph.D. Thesis, 1991, Drexel University, Philadelphia, PA.
“Spray Deposition of High-Strength Low-Alloy Steels,” M.S. Thesis, 1990, Drexel University, Philadelphia, PA.
“Mechanical Properties of Spray Cast High-Strength Low-Alloy Steels,” P/M into the 1990s, International Conference on Powder Metallurgy, Vol. 2, 1990, The Institute of Metals, London, England, p.31. Written with A. Lawley, and D. Apelian.
“Spray Deposition of High-Strength Low-Alloy Steels,” 47th Electric Furnace Conference Proceedings, 1990, The Iron and Steel Society, Warrendale, PA, p. 415.
“Spray Casting of High-Strength Low-Alloy Steels,” Advances in Powder Metallurgy, Volume 2, 1989, compiled by T.G. Gasbarre and W.F. Jandeska, Jr., Metal Powder Industries Federation, Princeton, NJ, p. 161. Written with A. Lawley and D. Apelian.
“Analysis of Spray Formed Alloy 625 via Transmission Electron Microscopy,” October 1987. Internal Publication, David Taylor Research Center, Naval Surface Warfare Center, Naval Sea Systems Command, U.S. Department of the Navy, Annapolis, MD.
Invited Presentations, Seminars, and Lectures:
“Steel, Aluminum and Stainless Steel: How Metal Properties Influence Formability,” PMA Sheetmetal Seminar, Cleveland, OH, September 2024.
“Risks of Generic Material Card Usage,” (with E. Billur & V. Millioto), Great Designs in Steel, sponsored by American Iron & Steel Institute, May 2024.
“Advanced High Strength Steels – Metallurgy”, “Advanced High Strength Steels – Formability,” and “Advanced High Strength Steels – Joining,” Auto/Steel Partnership, numerous seminars / webinars for A/SP member companies and suppliers, multiple times per year, 2019 through 2024.
“Steel Metallurgy and Formability,” Western Lake Erie Chapter, National Tooling and Manufacturing Association, April 2024.
“Stamping Higher Strength Steels – Grades and Stamping Challenges & Solutions,” PMA Stamping Higher Strength Steels Seminar, virtual, Feb 2024.
“Steel, Aluminum and Stainless Steel: How Metal Properties Influence Formability,” PMA Sheetmetal Seminar, Cleveland, OH, December 2023.
“New Press-Hardened Steels and Process Enhancements for Hot Stamping” (with E. Billur), PMA and MetalForming Magazine Hot Stamping Experience and Tech Tour, 29 November 2023, Holland, MI.
“Stamping Higher Strength Steels,” PMA Stamping Higher Strength Steels Seminar, Cleveland, October 2023.
“Steel, Aluminum and Stainless Steel: How Metal Properties Influence Formability,” PMA Sheetmetal Seminar, Cleveland, OH, September 2022.
“Recent Advances in High-Strength Steels,” Metal Stamping and Lubrication Technology Conference produced by PMA and MetalForming Magazine, 29 March 2022, Cincinnati, OH.
“Advanced High Strength Steels – Metallurgy” and “Advanced High Strength Steels – Formability,” Auto/Steel Partnership, numerous seminars / webinars for A/SP member companies and suppliers, starting in 2019 and continuing today.
“Sheet Metal Grade & Formability Webinar Series,” a multi-day webinar presented to multiple international Automotive Suppliers, 2021/2022
“Advanced High-Strength Steel Application Guidelines Specific to PHS” (with E. Billur), PMA and MetalForming Magazine Hot Stamping Experience and Tech Tour, 2 November 2021, Ann Arbor, MI.
“AHSS Application Guidelines from WorldAutoSteel: Updated, Expanded, and Online” (with E. Billur), Presented at 1st Executive Summit – Cost Efficient Lightweighting – Efficient Applications For AHSS & UHSS, 21 September 2021, Linz, Austria.
“AHSS Application Guidelines from WorldAutoSteel: Updated, Expanded, and Online,” Modern Steels Development And Modelling (MSDM) Symposium (online), organized by University of Applied Sciences – Upper Austria, July 2021; https://www.fh-ooe.at/campus-wels/msdm2021/
“Hot Stamping,” an intensive three-day seminar presented on-site at an international Tier-One Automotive Supplier, 2021
“Working With High-Strength Steels Virtual Seminar,” PMA Webinar Series, October 2020
“Recent Developments in Warm/Hot Stamping Of Steel & Aluminum” (with E. Billur), MetalForming Magazine Hot Stamping Experience Webinar Series, October 2020
“The Role of Engineered Lubricants in Advanced Auto Body Structure Construction,” PMA Lubrication Technology for Metal Formers & Die Shops, Novi, February 2020
“Stamping Higher Strength Steels,” PMA Stamping Higher Strength Steels Seminar, Detroit, December 2019
“Forming Steel, Aluminum and Stainless Steel,” PMA Sheetmetal Seminar, Grand Rapids, June 2019
Stamping Higher-Strength Steels Seminar (day-long session), Sponsored by Precision Metalforming Association (PMA), September 2018, Nashville, TN
Sheetmetal Forming of Steel, Aluminum, and Stainless Steels Two-Day Seminar (sole presenter), Sponsored by Precision Metalforming Association (PMA), June 2018, Cleveland, OH
“Fundamentals of Stamping and Joining Aluminum Alloys – An Introduction,” Sponsored by Precision Metalforming Association (PMA), Metal Stamping and Tool & Die Conference, January 2018, Nashville, TN
Stamping Higher-Strength Steels Seminar (day-long session), Sponsored by Precision Metalforming Association (PMA), July 2017, Detroit, MI
Sheetmetal Forming Technology Two-Day Seminar (sole presenter), Sponsored by Precision Metalforming Association (PMA), June 2017, Detroit, MI
“Tensile Testing for Sheet Metal Formability” and “Forming Limits and Strain Analysis,” Die-Design Software and Simulation-Technology Experience, Sponsored by Precision Metalforming Association (PMA), May 2017, Chicago, IL
“Are You a Lightweight or Do You Have Strength? Sheet Metal Lubricants are a Vehicle to Both,” Commercial Marketing Forum, Society of Tribologists and Lubrication Engineers Annual Meeting 2017, Atlanta, Georgia.
“Steel, Strength, Stamping and Specs – Profitability through Partnership”, Stamping Journal Forum: Productivity Process People Partnership: Stamping in the 21st Century, Hoffman Estates, IL, Sponsored by Fabricators & Manufacturers Association, Intl. (FMA), September 2010.
“Advanced High Strength Steels: Dual Phase, TRIP, Hot Stamping, Complex Phase,” Body-In-White Technology Forum, Body Engineering Group, Chrysler LLC, February 2010.
“Stamping Stainless Steel Sheets Successfully,” METALFORM/FABTECH 2008, Las Vegas, NV, Sponsored by Precision Metalforming Association, Fabricators & Manufacturers Association, Intl., and the Society of Manufacturing Engineers, October 2008.
“Advanced High Strength Steels,” FABTECH 2007, Chicago, IL, Sponsored by Fabricators & Manufacturers Association, Intl. (FMA), and the Society of Manufacturing Engineers (SME), November 2007.
“Introduction to Work Hardening and Edge Cracking of Advanced High Strength Steels,” 3rd Annual Stamping Journal Forum, Troy, OH, Sponsored by Fabricators & Manufacturers Association, Intl. (FMA), May 2005. With E.D. Bishop.
“Introduction to Work Hardening and Edge Cracking of Advanced High Strength Steels,” FABTECH 2004, Cleveland, OH, Sponsored by Fabricators & Manufacturers Association, Intl., and the Society of Manufacturing Engineers, October 2004. With E.D. Bishop.
“A Proactive Approach to Value-Added Stampings”, 2nd Annual Stamping Journal Forum: Competing to Win With Less, Troy, MI, Sponsored by Fabricators & Manufacturers Association, Intl. (FMA), May 2004. With B.E. Kowing.
“Advanced High Strength Steels,” FABTECH 2003, Chicago, IL, Sponsored by Fabricators & Manufacturers Association, Intl. (FMA), and the Society of Manufacturing Engineers (SME), November 2003.
“A/SP Dent Resistance Standardized Test Task Force,” Symposium on Bake Hardening Steels, Institute of Mechanics and Materials, Report 97-8, La Jolla, CA, March 1997.
“Dent Resistance Standardized Test Task Force-Project Overview” Auto/Steel Partnership Technical Communications Meeting, Warren, MI, February 21, 1997