Light Weighting 4.0

IIT M / Deakin / IITH

Agenda

• Setting the Context

• Topic 1: The present: Progress in Lighter Weight Materials and Manufacturing,

• Topic 2: Emerging capabilities in Advanced Materials, ML and AI for Lightweighting

• Closing Remarks

• Moderated Q&A

• Over 10 years of collaboration between Deakin and IITM

• CoE formed between Deakin, IITM in 2017 and IITH joined in 2019

• 12 Joint PhD / Masters students

• 12 publications, 1 patent, 2 projects

• Focus on Advanced Materials and Manufacturing, enabled by AI and ML

EXPLORE OUR WORLD..

Better

picture

100nm

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50N 60N 70N 100N 120N 150N 200N

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Normal Load

No GR/MOD

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MOD

GR+MOD

0 5 10 15 200

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Ageing time, 2hrs

Al100-X

FeX- 20h MA

Composition (at % Fe)

Hard

ness, G

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green compact

473K

573K

673K

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What is driving the changes?

Lightweighting:

Disruptive innovation in materials and design:

• to drive fuel efficiency,

• extend range in transportation and energy sectors

• nexus of regenerative design, visualization, advanced materials and

Industry 4.0

Capabilities

Here and Now Future

• Alloy Design (High Strength Steels)

• Composites design and manufacture

• Testing & Simulations

• Manufacturing – Sheet metal, castings, forgings

• Component and sub assembly design

• Hybrid components (metal and composites)

• High temperature Aluminum alloys

• High entropy alloys

• AI and ML driven disruptive designs

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IIT-MadrasCase studies:High Strength MetalsOptimisation

8

Light weighting automotive structures

Lightweight – key to reduced energy consumption (Gasoline, EV, Hybrid vehicles)

Development of technologies for multi-material BIW suited for mass production, esp. when composite materials are used;

CAE Predictive Models – Stiffness and Durability models, FMVSS (or equivalent) side impact, roof crush, frontal off-set

Development of technologies for repair and reassessment of structural integrity; recyclability of fibre composite structures.

Component level testing;

Durability testing using road simulators.Studies related to crash analysis – Dynamic buckling of sections for improved energy absorption

Aluminium extruded sections – empty column compression studies.Foam filled (Polymer, Al-metal foam) column compression studies;Design of geometries to enhance energy absorption.

Support to Indian Auto Industry – Material, component testing, Design validation, CAE analysis.

DEPARTMENT OF METALLURGICAL AND MATERIALS ENGINEERING

Research and Capabilities in the area of development

of Advanced High Strength Steels (AHSS) and

Aluminium alloys

Alloy design

Formability studies including anisotropy

measurements and stretch flangeability studies

Physical Simulation of forming, welding and heat

treatment processes using a GleebleTM Thermal-

Mechanical Simulator

Dept also hosts the Center of Excellence in Steel

Technology funded by Ministry of Steel, Govt of India

Surface Engineering and Corrosion Studies[Source : IS 16630: 2009, Metallic Materials –

Sheet and Strip – Hole expanding test]

Fig. 1. Schematic of hole expansion test

➢ Hot forming of B steels and simulations of process

using GleebleTM.

➢ Stretch flangeability determination of AHSS.

➢ Weldability of automotive steels and aluminium

alloys.

➢ Alloy design from thermo-dynamic principles (as

part of Steel Research Center)

Hybrid composite seat development for 2-W scooter –replacement of existing seat base with composite.

• M. Tech Automotive Technologies Student dissertation project (Won Lucas-TVS award)

• To replace an existing seat base of a scooter (Polypropylene) with hybrid composite (polymer based composite) – GFRP+CFRP

• Existing weight: 1170 g; estimated weight based on analysis using composite material: 560 g; achieved weight: 660g. Weight saving: ~ 40 %.

• Methods followed:• CAD model, revising CAD model for polymer composite (DFMA concepts),

Stress analysis, mold preparation, composite seat base preparation using hand-lay-up; testing for stiffness;

• Pending: durability test; impact / failure prediction.• Further Research: Joining methods of composites, metals etc.

• In general, research towards post-impact fatigue performance of polymer composites subjected to random/spectrum loading.

• Impact energy: 23J, 35J, 53 J; Drop-weight impactor• Use of multi-sensor approaches to understand damage progression (Stiffness,

IRT, CT, AE).

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DeakinCase studies:Composites andAdditive Manufacturing

12

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Materials

Digital Modelling

Manufacturing Processes

Lightweight Design

Sustainable Solutions

Lightweighting Webinar

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Materials

Digital Modelling

Manufacturing Processes

Lightweight Design

Composites

Lightweighting Webinar

The Future

Carbon Fibre Composites

LOW COST

3D Printing Composites

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Materials

Digital Modelling

Manufacturing Processes

Lightweight Design

Additive Manufacturing

Lightweighting Webinar

The Future

Powder extraction port

Links between voids

1. Engineering analysis2. Check AM

manufacturing constraints

3. Check powder removal constraints

3D Printing Tooling

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IIT Hyderabad Future Trends

16

• Increasing strength leads to reduced c/s area of

components

• Materials savings

• Energy savings

• Sustainable manufacturing and development ecosystem

Ultra high strength materials

Challenge

Heterostructured High Entropy Alloys (HEAs)

Strength or Ductility: Strength-ductility trade-off

Novel alloy and microstructural design strategies

Alloy discovery by Machine Learning

Periodic table cartoon from Deskarati

Collaborative Expertise across IITs/Deakin

Lighter Weight Metallic

Alloys

• Mg, Al, High Strength

steels, High Entropy

Alloys

• Processing –

Microstructure-

Property Relationships

• Deformation

Processing for Limited

Ductility Systems

Polymeric Composites

Materials

• Carbon and Glass

Fibers, Processing, Ply

Design

• Macrostructure-property

– relationships

• Design Methods with

Composites

Advanced

Manufacturing

• Deformation

Processing &

Simulation

• VR /Robotics for

Complex

Structures

• Additive

Manufacturing

• Composites

Manufacturing

ICME, AI / ML and Robotics cuts across disciplines

Our challenge to the audience

• Can you Identify two or three components/sub-assemblies that could be the targets for weight reduction?

• Short term through MS / M Tech projects• Long term through research plan

Contact us at: anandmapr@gmail.com or kopal.c@deakin.edu.au

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Q&A?

- CLOSING REMARKS: PROF. SAMPATH KUMAR

TECHNICAL QUESTIONS / CHALLENGES?- ON HOW TO WORK WITH US?

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THANK YOU