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Welding and joining of advanced dissimilar lightweight alloys

   Faculty of Engineering and Informatics

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  Dr Kavian Cooke  Applications accepted all year round  Self-Funded PhD Students Only

About the Project

The automotive industry’s interest in the use of lightweight materials has significantly increased in recent years due to an enhanced demand for fuel efficiency and clean green technologies that improve environmental conditions. A major industrial challenge in the automotive industry relates to the joining of dissimilar materials. Which includes; the dissimilar/hybrid joining of materials such as; aluminium, steel, high strength steel, composites, and thermoplastics. The existing challenge in joining dissimilar metals includes differences in the thermo-kinetic and mechanical properties of the material such as; crystal structure, melting point, and thermal conductivity.

This project will explore the application of nanotechnology to conventional welding and joining processes as a method of improving the properties of the joints produced.

Currently, all quality assessment of dissimilar joints/welds is conducted using destructive testing techniques. Unfortunately, these techniques are time-consuming and costly. The proposed research will bridge the gaps in the existing knowledge on the dissimilar joining of ultra-high-strength materials and materials of complex chemical properties.

Funding Notes

This project is advertised in relation to the research areas in Materials Engineering. The successful applicant will be expected to provide the funding for tuition fees, living expenses and maintenance.

Applicants should also be aware that Additional Research Costs of £5,000 per annum are required (above Tuition Fees and Living Expenses) for consumables.


1. Cooke, K.O.; Khan, T.I.; Oliver, G.D. Transient liquid phase diffusion bonding Al-6061 using nano-dispersed Ni coatings. Mater. Des. 2012, 33.

2. Patel, A.R.; Dalwadi, C.G.; Rana, H.G. A Review: Dissimilar Material Joining of Metal to Polymer using Friction Stir Welding (FSW). IJSTE -International J. Sci. Technol. Eng. 2016.

3. Carlone, P.; Astarita, A.; Rubino, F.; Pasquino, N. Microstructural Aspects in FSW and TIG Welding of Cast ZE41A Magnesium Alloy. Metall. Mater. Trans. B Process Metall. Mater. Process. Sci. 2016.

4. Liu, L.; Ren, D. A novel weld-bonding hybrid process for joining Mg alloy and Al alloy. Mater. Des. 2011.
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