Dr. Willian Carvalho

• Research & Development • New Technologies & Incubation Lab

• Technical leadership of research project proposals, including structuring the projects, assembling the consortia (with academic and industrial partners), proposal preparation and application. • Coordination and execution of industrial projects. • Presentations at several national and international conferences, and other events. • Preparation and application of patents. • Development of AM metal-composite hybrid joints produced via ultrasonic joining. • Direct supervision of master and bachelor students.

• Equipment development and processes optimization for the production of automotive sensors, such as MAP, TPS and oxygen sensors. • Welding parameters optimization by statistical design of experiments (DoE). • Development of a stacking machine for the production of different sensors. • Optimization of automated assembling processes of different sensors to increase the production rate.

• RFSSW parameters optimization by DoE for AA6016-T4/DP600 dissimilar welds. • Investigation of the combination of solid-state welding processes with structural adhesives for automotive applications. • Mechanical and microstructural characterization of aluminum-steel dissimilar welds. • Development of an integrated multi-material aircraft section to demonstrate the techniques researched in the department. • Support the elaboration of the first draft of the ISO 18785 "Friction Stir Spot Welding - Aluminum".

• FE mechanical simulations and model optimization for the injection molding process of 50% and 60% long-glass-fiber reinforced polyamide 6 and 66. • Improvement of current mathematical prediction models of fiber orientation and fiber length degradation in the injection molding process of composites. • Analysis and validation of the simulation results with experimental tests.

• FE simulation of residual stresses in milling and turning processes for different materials. • Surface roughness and hardness measurements of machined components. • Force and temperature measurements during machining processes with tailor-made equipment.

• Research fields: Amorphous and biomedical alloys, and surface coatings. • Processing and material characterization of different alloys via: Vacuum arc melting furnace, melt spinning, scanning electron and optical microscopy, hardness testing, differential scanning calorimetry and x-ray diffraction.

• Baja SAE is a design competition run by the Society of Automotive Engineers (SAE). Teams of undergraduate students from universities all over the world design and build small off-road cars, and compete in different challenges divided in different phases. • Coordination of the Baja structure development and modelling group, leading the design of the vehicle's structure and the simulation of different components using FE simulation.

• Responsible for the maintenance of several machines and machining different components.

- Specialization: Composite, polymer and metallic materials; Additive manufacturing; Solid-state and friction-based welding and joining techniques; Materials characterization. - PhD Thesis: Ultrasonic joining of additively manufactured metal-composite hybrid for aircraft structures.

- Specialization: Metallic materials. - Exchange student for 2 semesters sponsored by the Coordination for the Improvement of Higher Education Personnel (CAPES). - Master Thesis: Analysis of residual stress generated by multiple cuts in the 18CrNiMo7-6 steel.

- Specialization: Composite and metallic materials. - Master Thesis: Simulation and experimental verification of mechanical properties of injection-molded 50% and 60% long-glass-fiber-reinforced polyamide-66 composites.