• Design and Manufacture of Multi-Material Lightweight Structures

Icon - Car Body

Driven not only by concerns over energy consumptions and environmental impact, but also by increasingly stringent product performance and safety requirements, the adoption of multi-materials lightweight structures has become imperative for the transportation industry. This course starts with the state of the art overview of recent lightweighting trends in various transportation industry sectors. We will then highlight some of the unique challenges in the design and manufacture of multi-material lightweight structures. We will focus on some basic considerations in material selections, dissimilar materials joining methods, and joint performance characterization methods. Finally, we will critically review emerging material joining technologies, including advanced analysis techniques, for potential future applications. Various real-world examples will be used throughout this course.


Learning Objectives


After completing this online course, you should be able to:

  • Understand current trends in manufacturing lightweight structural components

  • Become knowledgeable about the range of available lightweight materials and manufacturing processes

  • Appreciate how ICME models can optimize product design and manufacturing

  • How to select the appropriate material and manufacturing process for each component



  • Structural Lightweighting Trends and Multi-Material Structures
    (28 min)

  • Major Challenges in Design and Manufacturing of Multi-Material Structure
    (51 min)

  • Major Lightweight Structure Materials, Applications, and Combinations
    (47 min)

  • Dissimilar Metals Joining Techniques: Principles and Applications
    (64 min)

  • Polymer/Metal Joining Techniques: Principles and Applications
    (24 min)

  • Principles for Joint Design and Applications for Dissimilar Metal Joining
    (54 min)

  • Joint Stress Concentration Analysis Method for Fatigue Evaluation and Test Data Correlation: Part I
    (28 min)

  • Joint Stress Concentration Analysis Method for Fatigue Evaluation and Test Data Correlation: Part II
    (45 min)



Pingsha Dong
Pingsha Dong
Program Director

Dr. Dong’s teaching and research interests include advanced design and analysis methodologies for engineering structures with an emphasis on welded structures and novel computational modeling techniques for manufacturing processes. He has developed numerous unique computational procedures that have been adopted by major manufacturing industries and National/International Codes & Standards. These include the mesh-insensitive structural stress method for fatigue design and life evaluation of welded structures adopted by 2007 ASME Div 2 International Code, the Joint 2007 ASME FFS-1/API 579 RP-1 Fitness for Service Code. Dr. Dong has published about 200 papers in peer-reviewed archive journals and major conference proceedings, giving over two dozens of Plenary/Keynote Lectures at major international conferences.