Design Clinic: Corrosion evolution studies of dissimilar aluminum to steel using different sample configuration joining/welding

The objective of this project is to develop the precise understanding required to develop and explore new environmentally-compliant and economically viable solutions to i) enhance surface properties and performance, including reduced corrosion susceptibility, ii) facilitate joining of dissimilar materials (e.g. dissimilar metals) and the manufacture of hybrid structures and iii) protect multi-material structures, thus facilitating the introduction of more efficient designs. 1. Environmental Corrosion Simulation for a life expectancy of 10 years (sixty cycles of the CCT corrosion test): will include cyclic salt spray (wet/dry) testing for combination of joints that the number is determined by the capacity of the salt bath. Faraday Future will be providing proper hangers to maximize the capacity of the bath. 2. Visual Observation: will be carried out with optical facility and taking images for selected samples. 3. Mechanical Assessment: lap shear strength will be carried out for majority of corroded samples, after corrosion tests. 4. Microstructural Evaluation Analysis: samples from critical parameters (up to 25% of the entire corroded ones) will be selected to understand the microstructural behavior under resistance spot welding process. Selective sample will be undergone for SEM/EDS analysis.