Hongyan Zhang

Prof. Hongyan Zhang is a Professor at the School of Intelligent Manufacturing Ecosystem, Xi’an Jiaotong–Liverpool University (XJTLU), and an Adjunct Professor at the University of Toledo, USA. He has over three decades of experience in manufacturing science and engineering, with a particular focus on welding processes, materials joining, and physics-informed modeling.

Before joining XJTLU, Prof. Zhang served as a tenured professor at the University of Toledo for more than 25 years, and earlier as an assistant research professor at the University of Michigan. He also has substantial industrial experience, including serving as Chief Technology Officer (CTO) at Zotye Automotive Group, where he led advanced manufacturing and technology development initiatives.

Prof. Zhang is internationally recognized for his contributions to resistance welding. He is the co-author of the widely cited book Resistance Welding: Fundamentals and Applications (CRC Press), which is regarded as a standard reference in the field. His research has addressed key issues such as weld expulsion mechanisms, current shunting effects, and process stability in automotive manufacturing. He has also contributed to industry standards, including AWS/SAE/ANSI D8.9M.

His recent work focuses on physics-informed machine learning (PI+ML), a framework that integrates first-principles models with data-driven residual correction. This approach aims to improve predictive accuracy while maintaining physical interpretability, particularly for complex manufacturing processes such as welding, forming, and machining.

At XJTLU, Prof. Zhang’s research centers on:

• Cross-process modeling in manufacturing systems (forming–assembly–joining)
• Digital twin technologies for intelligent manufacturing
• AI applications in industrial processes, especially in new energy vehicle production
• Physics-informed hybrid modeling for small-data environments

He has authored numerous journal publications and holds over 80 patents (including more than 20 filed after joining XJTLU). His work bridges fundamental theory and industrial practice, with ongoing collaborations across academia and industry.