TY - JOUR

T1 - A Numerical Study on Co-Extrusion to Produce Coaxial Aluminum-Steel Compounds with Longitudinal Weld Seams

AU - Behrens, Bernd Arno

AU - Klose, Christian

AU - Chugreev, Alexander

AU - Heimes, Norman

AU - Thürer, Susanne Elisabeth

AU - Uhe, Johanna

N1 - Funding information: This research was funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) grant number 252662854. The APC was funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation). The results presented in this paper were obtained within the Collaborative Research Centre 1153 “Process chain to produce hybrid high performance components by Tailored Forming” in the subproject A01, funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation)—252662854. The flow curves presented in this paper were obtained in cooperation with subproject C1 of the Collaborative Research Centre 1153. The authors thank the German Research Foundation (DFG) for their financial support of this project.

PY - 2018/9

Y1 - 2018/9

N2 - The use of lightweight materials is one possibility to limit the weight of vehicles and to reduce CO2 emissions. However, the mechanical properties and weight-saving potential of mono-materials are limited. Material compounds can overcome this challenge by combining the advantages of different materials in one component. Lateral angular co-extrusion (LACE) allows the production of coaxial semi-finished products consisting of aluminum and steel. In this study, a finite element model of the LACE process was built up and validated by experimental investigations. A high degree of agreement between the calculated and experimentally determined forces, temperatures, and the geometrical shape of the hybrid profiles was achieved. In order to determine suitable parameters for further extrusion experiments, the influence of different process parameters on material flow and extrusion force was investigated in a numerical parametric study. Both the temperature and extrusion ratio showed a significant influence on the occurring maximum extrusion force as well as the material flow inside the LACE tool. The maximum force of 2.5 MN of the employed extrusion press was not exceeded. An uneven material flow was observed in the welding chamber, leading to an asymmetric position of the steel rod in the aluminum matrix.

AB - The use of lightweight materials is one possibility to limit the weight of vehicles and to reduce CO2 emissions. However, the mechanical properties and weight-saving potential of mono-materials are limited. Material compounds can overcome this challenge by combining the advantages of different materials in one component. Lateral angular co-extrusion (LACE) allows the production of coaxial semi-finished products consisting of aluminum and steel. In this study, a finite element model of the LACE process was built up and validated by experimental investigations. A high degree of agreement between the calculated and experimentally determined forces, temperatures, and the geometrical shape of the hybrid profiles was achieved. In order to determine suitable parameters for further extrusion experiments, the influence of different process parameters on material flow and extrusion force was investigated in a numerical parametric study. Both the temperature and extrusion ratio showed a significant influence on the occurring maximum extrusion force as well as the material flow inside the LACE tool. The maximum force of 2.5 MN of the employed extrusion press was not exceeded. An uneven material flow was observed in the welding chamber, leading to an asymmetric position of the steel rod in the aluminum matrix.

KW - Aluminum-steel compound

KW - Co-extrusion

KW - FEM

KW - Tailored forming

UR - http://www.scopus.com/inward/record.url?scp=85053782955&partnerID=8YFLogxK

U2 - 10.3390/met8090717

DO - 10.3390/met8090717

M3 - Article

AN - SCOPUS:85053782955

VL - 8

JO - Metals

JF - Metals

SN - 2075-4701

IS - 9

M1 - 717

ER -