TY - CONF

T1 - Tailored forming technology for three dimensional components

T2 - 5th International Conference on ThermoMechanical Processing, TMP 2016

AU - Behrens, Bernd Arno

AU - Bouguecha, Anas

AU - Frischkorn, Conrad

AU - Huskic, Adis

AU - Stakhieva, Anna

AU - Duran, Deniz

PY - 2016

Y1 - 2016

N2 - The continuous need for lightweight components calls for a means to extensively utilise lighter three dimensional components in design and production without compromising on the strength. In order to address this need, suitable process chain possibilities to manufacture high performance hybrid components are being researched at Leibniz Universität Hannover in the context of the Collaborative Research Centre (CRC) 1153. In the construction of hybrid components in the CRC 1153, two different materials are essentially involved; one of which is of higher mechanical strength and situated in the area under loading (mainly steel variants), whereas the rest of the bulk is constituted by the lightweight material (mainly aluminium alloy variants). In first step of the process chain, hybrid semi-finished workpieces are manufactured by joining the two materials using a process such as friction welding, laser welding or compound extrusion. As a result of joining, the joining zone is accompanied by irregular microstructure and brittle intermetallic phases. Therefore, it should be treated by thermomechanical processing during forming; otherwise, the manufactured components are likely to fail in operation. The primary challenge for forming is a suitable tooling design that is supposed to provide a good control over the joining zone. Moreover, a tailored heating strategy is required to obtain a material-specific initial temperature distribution along the semi-finished hybrid workpieces. In this paper, associated solution approaches to these challenges are presented for two different hybrid components: a bearing bushing and a stepped shaft.

AB - The continuous need for lightweight components calls for a means to extensively utilise lighter three dimensional components in design and production without compromising on the strength. In order to address this need, suitable process chain possibilities to manufacture high performance hybrid components are being researched at Leibniz Universität Hannover in the context of the Collaborative Research Centre (CRC) 1153. In the construction of hybrid components in the CRC 1153, two different materials are essentially involved; one of which is of higher mechanical strength and situated in the area under loading (mainly steel variants), whereas the rest of the bulk is constituted by the lightweight material (mainly aluminium alloy variants). In first step of the process chain, hybrid semi-finished workpieces are manufactured by joining the two materials using a process such as friction welding, laser welding or compound extrusion. As a result of joining, the joining zone is accompanied by irregular microstructure and brittle intermetallic phases. Therefore, it should be treated by thermomechanical processing during forming; otherwise, the manufactured components are likely to fail in operation. The primary challenge for forming is a suitable tooling design that is supposed to provide a good control over the joining zone. Moreover, a tailored heating strategy is required to obtain a material-specific initial temperature distribution along the semi-finished hybrid workpieces. In this paper, associated solution approaches to these challenges are presented for two different hybrid components: a bearing bushing and a stepped shaft.

KW - Extrusion

KW - Forging

KW - Induction heating

KW - Joining zone

KW - Tailored forming

UR - http://www.scopus.com/inward/record.url?scp=85014415804&partnerID=8YFLogxK

M3 - Paper

Y2 - 26 October 2016 through 28 October 2016

ER -