Remote Laser Welding of Dissimilar Metals for Automotive Structural Applications

项目目标：该博士项目将在远程激光焊接(RLW)过程中产生不同材料连接(即钢与铝结构)领域的知识。在项目期间，我们将研究金属间化合物的形成，以实现结构应用的持久连接。挑战规模：由于其高产量和灵活性，RLW正越来越多地被汽车行业采用，使焊接过程更快、更准确，并减少热影响区。我们已经验证了铝板的连接；我们正在对结构应用中的铝铸件和挤压件进行验证。下一个挑战是连接不同的金属(从钢到铝结构)。缺乏对能够实现持久连接的正确金属间化合物(IMC)的有效控制是阻碍这项技术在大规模生产中充分采用的限制因素，特别是在结构应用中。该项目将必须克服这一挑战，以确保在未来的计划中正确实施针对不同金属的RLW工艺。目标：本博士项目的具体目标是：审查现有的控制IMC形成的方法/技术解决方案开发控制IMC形成的新方法(焊接技术)用CAE模拟来补充实验研究以预测通常不能直接用实验测量的金属混合用符合EPSRC和国家产业战略的相关材料(合金和核心应用将根据捷豹路虎的输入进行改进)验证和验证所提出的方法：该项目直接涉及ESPRC的主题“制造未来”。它还直接为ESPRC的研究领域做出贡献，如制造技术和材料工程。该项目还将支持英国政府的“零排放之路”战略和英国政府于2020年11月发起的“10点计划”，解决轻量化车辆和电子机动性问题，并加快将其推向市场，重点是降低成本和提高可靠性和安全性，同时加快零缺陷和零浪费战略，以及更多地采用可回收材料。

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 formationTo develop novel methods (welding techniques) to control IMC formationTo complement experimental investigation with CAE simulation to predict metal mixing, typically not directly measurable with experimentsVerification 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.