Within IRDL, Amen Benali has developed a method to optimize bonded assemblies in automotive structures.
Amen Benali, chercheur·e au sein de IRDL (Institut National Polytechnique de Bretagne).
Thèse soutenue en 2025 à l'école doctorale École doctorale Sciences pour l'ingénieur et le numérique.
Référencée dans le réseau ABES/STAR, cette thèse répond aux critères de rigueur de l'enseignement supérieur français.
The optimization of bonded assemblies in the automotive sector represents a major challenge, not only to reduce vehicle weight but also to maintain their performance while meeting increasing environmental requirements. Amen Benali's thesis, titled "Sizing Method for Bonded Assemblies in an Engine Cradle Structure," addresses this issue with an innovative approach that could redefine industry standards. Indeed, the use of lightweight materials such as aluminum, in place of traditional steel, could allow for a significant reduction in the weight of structures, reaching up to 50%. This weight reduction has direct implications for fuel consumption and CO2 emissions, a hot topic in the current context of the fight against climate change, where every gram counts in the carbon footprint of vehicles.
Benali's work highlights aspects often overlooked in previous studies, such as edge effects and surface treatment on bonded joints. These factors, although sometimes considered secondary, play a crucial role in the overall performance of assemblies. By integrating advanced modeling methods and experimental analyses, it becomes possible to improve the understanding of failures in bonded assemblies. For example, the Reflectance Transformation Imaging (RTI) technique used to analyze fracture faces offers precise visualization of failures, thus allowing for the optimization of substrate design. This represents a significant advancement over traditional methods, often limited by more simplistic approaches.
The preliminary results of this research are promising. By replacing steel with aluminum, not only is weight reduced, but the durability of structures is also improved. This improvement in durability is essential in an automotive sector that is under pressure to reduce its greenhouse gas emissions. Indeed, the durability of materials used in automotive construction is a key factor in ensuring the longevity of vehicles while minimizing their environmental impact. The strategic recommendations arising from this research include optimizing substrates to minimize stress concentrations at free edges, which could have a significant impact on the performance of bonded assemblies.
However, this research raises important questions. How can manufacturers integrate these new methods into their production processes? What challenges must be overcome to adopt these technologies on a large scale? For example, the transition to lighter materials such as aluminum requires not only technical adjustments but also a reconsideration of supply chains and manufacturing methods. Decision-makers must also think about how to support this transition, particularly through incentive policies and funding for research and development. Initiatives such as grants for companies investing in more sustainable technologies could play a crucial role in this transition.
In summary, Amen Benali's work paves the way for lighter and more efficient solutions for automotive structures, thereby contributing to the reduction of greenhouse gas emissions and improving vehicle durability. It is crucial that stakeholders in the automotive sector take these advancements into account to remain competitive in the global market. In a context where the pressure to innovate and reduce environmental impact is stronger than ever, this research could well be the necessary catalyst to transform the automotive industry. By integrating these new methods and adopting a proactive approach to environmental challenges, the automotive sector could not only improve its performance but also play a leading role in the fight against climate change.
Données clés
- 50% : Réduction du poids des structures automobiles en remplaçant l'acier par de l'aluminium.
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Sources et accès
Amen Benali. Méthode de dimensionnement d’assemblages collés dans une structure de berceau moteur : Prise en compte des effets de bords dans la méthode par l’utilisation de gradients de propriétés mécaniques dans la modélisation de l’adhésif et évaluation des faciès de rupture par imagerie de transformation par réflectivité. Matériaux. École Nationale Supérieure de Techniques Avancées, 2025. Français. ⟨NNT : 2025ESTA0007⟩. ⟨tel-05467818⟩