The future of India's electric vehicle (EV) market is set to soar, according to the Economic Survey 2023, projecting a noteworthy 49% compound annual growth rate (CAGR) from 2022 to 2030. This rapid growth is expected to result in an impressive 10 million annual sales by 2030. While the potential for success is evident, there remains a critical challenge in dealing with the widespread fear of inadequate battery range among potential consumers.

To address this concern and improve overall energy efficiency, the key lies in the practice of light weighting EVs. Even a small 10% reduction in curb weight can result in a significant 6-8% decrease in energy consumption, making EVs not only more attractive, but also more environmentally sustainable. Cutting-edge materials such as Ultra High Strength steels for automobiles, Aluminum alloys, Magnesium alloys for vehicle frames, and advanced composites like carbon fiber reinforced plastics for key components such as the roof, firewall, battery tray, and covers are key to accomplishing our objective of reducing weight.

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orporating state-of-the-art materials into electric vehicles calls for cutting-edge joining methods to seamlessly introduce them. This not only allows for the creation of lightweight components with exceptional strength-to-weight ratios, but it is also essential for maximizing performance. Embracing lightweight materials in the automotive field brings a twofold benefit: shedding vehicle weight and improving aerodynamics. As a result, this results in reduced fuel usage, ultimately reducing the release of harmful pollutants and particles.

In this paper, we present study of workshop trials and qualification of advanced joining processes such as laser welding, welding of new High Strength and Ultra-High Strength Steels, Aluminum welding, Adhesive Bonding of polymers and Electric Resistance Spot Welding of the new generation materials. Finally, a discussion is made on the different applications of these joining processes. Hence, the details presented in this study should be useful for automobile companies to align with requirements of new generation joining processes for light weighting.

This article is shared by Vijay Bhalerao and Dr. Anurag Nema