Research Projects

The automobile industry is transforming to produce lighter, more fuel-efficient vehicles due to a global drive to reduce carbon emissions. This can be achieved through downsizing, efficient design, and the use of lightweight materials. A 10% weight reduction in vehicles can decrease fuel consumption by around 7%. As the automotive body accounts for over 40% of the vehicle's overall weight, the industry is focusing on lightweight vehicle body materials. Metal-polymer hybrid structures, such as M-P-M (metal-polymer-metal) layered sandwiches, offer lightweight alternatives with excellent specific strength, stiffness, and acoustic and vibration dampening properties. M-P-M composite manufacturing technologies include adhesive bonding and warm roll bonding, which are sensitive to service temperature, aging, and environmental conditions. Laser bonding of metal to polymer is a viable option, but its use in the manufacture of M-P-M sandwich composites has not been examined. This work proposes to produce M-P-M sandwich composites using laser-based fusion technology and develop design and manufacturing guidance for laser-based manufacturing. The mechanical performance and forming behavior of custom-made laser-bonded M-P-M sandwich composites will be characterized, evaluated, and compared to monolithic materials. A finite element model will be developed to anticipate acceptable process conditions and optimize the process to yield better performance indices.