Remote Laser Welding of Dissimilar Metals for Automotive Structural Applications

Project aim: this PhD project will generate knowledge in the area of dissimilar material joining (i.e., steel to aluminium structures) with Remote Laser Welding (RLW) process. During the project we will study the formation of intermetallic compounds to enable a durable join for structural applications.
Scale of challenge: RLW is increasingly being adopted within the automotive industry due to its high production throughput and flexibility, making the welding process much faster and more accurate, with reduced heat affected zones. We have already validated the joining of aluminium sheets; and we are working through the validation of aluminium castings and extrusions, for structural applications. Joining of dissimilar metals (steel to aluminium structures) is the next challenge. The lack of efficient control of right intermetallic compound (IMC) that will enable a durable join is a limiting factor preventing the full uptake of this technology in mass production, especially for structural applications. The project will have to overcome that challenge to ensure the right implementation of RLW process to dissimilar metals in future programs.
Objectives: specific objectives of this PhD project are:
Review existing methods/technological solutions to control IMC formation
To develop novel methods (welding techniques) to control IMC formation
To complement experimental investigation with CAE simulation to predict metal mixing, typically not directly measurable with experiments
Verification and validation of proposed methods with relevant materials (alloys and core applications to be refined based on JLR's input)
Fit to EPSRC and national industrial strategy: the project directly addresses the ESPRC theme "Manufacturing the Future". It also directly contributes to ESPRC research areas such as Manufacturing Technologies and Materials Engineering. The project will also support the UK Government "Road to Zero" strategy and the "10 Point Plan" launched by the UK government in November 2020 by addressing lightweight vehicles and e-mobility, as well as by speeding up their introduction to the market with focus on cost reduction and increased reliability and safety, whilst accelerating strategies for zero-defect and zero-waste as well as increasing the adoption of recycled materials.