Joining of light weight hybrid structures [Phase I]

The higher demand on fuel-efficient transportation increased the need for lightweight hybrid structures in subassemblies. Due to their lighter weight, polymeric composites, nanocomposites, and polymer-metal structures are being increasingly used in several transportation related products to reduce energy and fuel consumption leading to lower CO2 emissions. Conventional practice is to assemble these hybrid structures using fasteners and adhesive bonding which have some limitations, such as pre-joining preparation; drilling holes, added weight from fasteners, induced stress concentrations etc. The challenge is to be able to join plastics and their composites with light materials such as Al, Mg to form useful complex and sturdy structures. This research work will help increase the utilization of hydrocarbon-based materials in a large number of industries and mainly the transportation industry. It will contribute to localizing manufacturing within the Kingdom in the sectors of hydrocarbon-based materials and hybrids. Moreover, Developing the technologies of friction lap welding (FLW) and friction stir welding (FSW) of similar (polymer-polymer) and dissimilar (polymer-composites-metals) materials will benefit many industries in the Kingdom. The overall aim of this work is to develop the technology for joining similar and dissimilar polymers, polymers to light metals and polymer and metals to polymer composites and nanocomposites. The latter will be designed and synthesized during the second phase of this research. The project will include a complete investigation of all the aspects and multiphysics phenomena involved in such manufacturing processes and the performance of the resulting structures.