Research Projects

Hybrid electric vehicles (HEVs) have gained popularity due to their eco-friendliness and the reduction of carbon dioxide emissions in the transport sector. Many countries are encouraging the use of HEVs, leading to increased production of lightweight components, particularly aluminum alloy-based components like busbars, drive shafts, crash boxes, and pressure vessels. To make aluminium alloy functionally suitable for these applications, it must be integrated with other materials like copper and steel. Fusion welding processes are applied to weld aluminium alloys with stainless steels and copper alloys. However, laser beam welding (LBW) forms intermetallic compounds with high specificity, resulting in reduced power transference and low energy efficiency. Electron beam welding (EBW) evaporates elements like Zn and Mg due to its low melting point, causing wider weld bead and coarser grains. Gas tungsten arc (GTA) and gas metal arc (GMA) processes require post-cleaning for aesthetic appearance and are associated with wider HAZ formation. Solid state welding techniques like Ultrasonic Welding (USW) and Friction Stir Welding (FSW) are typically used for this purpose. However, FSW produces wider TMAZ and brittle intermetallic compounds, which must be monitored carefully to avoid improper welding and defective joints. This project aims to join components of hybrid electric vehicles using Magnetic Pulse Welding (MPW), which produces an HAZ-free joint. The proposal also aims to design magnetic coils and field shapers for MPW, evaluate its effect on mechanical properties and microstructural characteristics, and establish a process window for increased productivity, structural integrity, and reliability.