Date of Award


Document Type


Degree Name

Doctor of Philosophy (PhD)

Legacy Department

Automotive Engineering


Dr. Fadi Abu-Farha

Committee Member

Dr. Thomas Kurfess

Committee Member

Dr. Laxmikant Saraf

Committee Member

Dr. Marian S. Kennedy

Committee Member

Dr. Srikanth Pilla


The overall objective of this research is to develop the microstructure of metallic lightweight materials via multiple advanced processing techniques with potentials for industrial utilization on a large scale to meet the demands of the aerospace and automotive sectors. This work focused on (i) refining the grain structure to increase the strength, (ii) controlling the texture to increase formability and (iii) directly reducing processing/production cost of lightweight material components. Advanced processing is conducted on a bulk scale by several severe plastic deformation techniques including: accumulative roll bonding, isolated shear rolling and friction stir processing to achieve the multiple targets of this research. Development and validation of the processing techniques is achieved through wide-ranging experiments along with detailed mechanical and microstructural examination of the processed material. On a broad level, this research will make advancements in processing of bulk lightweight materials facilitating industrial-scale implementation. Where accumulative roll bonding and isolated shear rolling, currently feasible on an industrial scale, processes bulk sheet materials capable of replacing more expensive grades of alloys and enabling low-temperature and high-strain-rate formability. Furthermore, friction stir processing to manufacture lightweight tubes, made from magnesium alloys, has the potential to increase the utilization of these materials in the automotive and aerospace sectors for high strength - high formability applications. With the increased utilization of these advanced processing techniques will significantly reduce the cost associated with lightweight materials for many applications in the transportation sectors.