Study and experimental characterization of the laser welding process for the manufacturing of electric powertrain components in the automotive industry

The PhD project that will be presented in this thesis is focused on the study and optimization of the production process for the manufacturing of electrical powertrain components in the automotive field using the laser beam welding process (LBW). The objective is to define, through experimental activities, an optimized process condition for applications in the electrical field that can be generalized, that is, which guarantees its reproducibility as the types of connections vary and which represents the basis for extending the method to future applications in e-mobility sector. The work developed along two lines of research, the convergence of which made it possible to create prototypes of battery modules based on different types of lithium-ion cells and stator windings for electric motors. On the one hand, the different welding configurations involving the production of batteries based on pouch cells and therefore the welding of aluminum and copper in dissimilar configuration were studied, while for the prismatic cells only one configuration was analyzed. On the other hand, the welding of pure copper hairpins with rectangular shape in edge joint configuration was studied for the production of stator windings. The experimental tests carried out have demonstrated the feasibility of using the LBW process for the production of electric powertrain components entirely designed and developed internally as the types of materials and welding configurations vary; the methodologies required for the characterization methods, necessary for the end-of-line tests, for the evaluation of the properties of the different joint configurations and components (battery and electric motor) were also defined with the aim of obtaining the best performance. The entire doctorate program was conducted in collaboration with Ferrari Auto S.p.A. and the direct industrial application of the issues addressed has been faced.

First steps in underwater photogrammetry with the support of an unmanned underwater vehicle

The evolution of modern and increasingly sensitive image sensors, the increasingly compact design of the cameras, and the recent emergence of low-cost cameras allowed the Underwater Photogrammetry to become an infallible and irreplaceable technique used to estimate the structure of the seabed with high accuracy. Within this context, the main topic of this work is the Underwater Photogrammetry from a geomatic point of view and all the issues associated with its implementation, in particular with the support of Unmanned Underwater Vehicles. Questions such as: how does the technique work, what is needed to deal with a proper survey, what tools are available to apply this technique, and how to resolve uncertainties in measurement will be the subject of this thesis. The study conducted can be divided into two major parts: one devoted to several ad-hoc surveys and tests, thus a practical part, another supported by the bibliographical research. However the main contributions are related to the experimental section, in which two practical case studies are carried out in order to improve the quality of the underwater survey of some calibration platforms. The results obtained from these two experiments showed that, the refractive effects due to water and underwater housing can be compensated by the distortion coefficients in the camera model, but if the aim is to achieve high accuracy then a model that takes into account the configuration of the underwater housing, based on ray tracing, must also be coupled. The major contributions that this work brought are: an overview of the practical issues when performing surveys exploiting an UUV prototype, a method to reach a reliable accuracy in the 3D reconstructions without the use of an underwater local geodetic network, a guide for who addresses underwater photogrammetry topics for the first time, and the use of open-source environments.