Details
Original language | English |
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Journal | Advanced engineering materials |
Early online date | 15 Jan 2025 |
Publication status | E-pub ahead of print - 15 Jan 2025 |
Abstract
Processing of hybrid materials is particularly challenging due to the different physical properties and requires extensive knowledge to produce defect-free components. When serially combining steel and aluminum through rotary friction welding and subsequent cup backward extrusion in Tailored Forming, the strongly different yield stresses are a decisive factor. The following study analyzes the temperature and stress distribution after the compensatory heating step with additional cooling and during cup backward extrusion within a preform of a hybrid hollow shaft using experimental heating tests and finite element simulations. The influence on the bond strength is quantified by uniaxial tensile tests along the interface. Compared to uncooled samples, local cooled samples exhibit higher compressive stresses in the joining zone and hence higher forming resistance due to higher temperature gradients. Therefore, delamination and cracks can be prevented. While areas at the edge or in the center indicate reduced strengths overall, areas with high surface enlargement do not fail in the joining zone, but in the base material of the aluminum. To further enhance process stability and process control measures, a preliminary concept for the implicit determination of component temperatures using integrated sensor systems on the handling system is presented.
Keywords
- cup backward extrusion, finite element simulations, handling, rotary friction welding, tailored forming
ASJC Scopus subject areas
- Materials Science(all)
- General Materials Science
- Physics and Astronomy(all)
- Condensed Matter Physics
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In: Advanced engineering materials, 15.01.2025.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Analysis of Temperature and Stress Distribution on the Bond Properties of Hybrid Tailored Formed Components
AU - Piwek, Armin
AU - Ortlieb, Eduard
AU - Ince, Caner Veli
AU - Peddinghaus, Julius
AU - Wester, Hendrik
AU - Uhe, Johanna
AU - Raatz, Annika
AU - Brunotte, Kai
N1 - Publisher Copyright: © 2025 The Author(s). Advanced Engineering Materials published by Wiley-VCH GmbH.
PY - 2025/1/15
Y1 - 2025/1/15
N2 - Processing of hybrid materials is particularly challenging due to the different physical properties and requires extensive knowledge to produce defect-free components. When serially combining steel and aluminum through rotary friction welding and subsequent cup backward extrusion in Tailored Forming, the strongly different yield stresses are a decisive factor. The following study analyzes the temperature and stress distribution after the compensatory heating step with additional cooling and during cup backward extrusion within a preform of a hybrid hollow shaft using experimental heating tests and finite element simulations. The influence on the bond strength is quantified by uniaxial tensile tests along the interface. Compared to uncooled samples, local cooled samples exhibit higher compressive stresses in the joining zone and hence higher forming resistance due to higher temperature gradients. Therefore, delamination and cracks can be prevented. While areas at the edge or in the center indicate reduced strengths overall, areas with high surface enlargement do not fail in the joining zone, but in the base material of the aluminum. To further enhance process stability and process control measures, a preliminary concept for the implicit determination of component temperatures using integrated sensor systems on the handling system is presented.
AB - Processing of hybrid materials is particularly challenging due to the different physical properties and requires extensive knowledge to produce defect-free components. When serially combining steel and aluminum through rotary friction welding and subsequent cup backward extrusion in Tailored Forming, the strongly different yield stresses are a decisive factor. The following study analyzes the temperature and stress distribution after the compensatory heating step with additional cooling and during cup backward extrusion within a preform of a hybrid hollow shaft using experimental heating tests and finite element simulations. The influence on the bond strength is quantified by uniaxial tensile tests along the interface. Compared to uncooled samples, local cooled samples exhibit higher compressive stresses in the joining zone and hence higher forming resistance due to higher temperature gradients. Therefore, delamination and cracks can be prevented. While areas at the edge or in the center indicate reduced strengths overall, areas with high surface enlargement do not fail in the joining zone, but in the base material of the aluminum. To further enhance process stability and process control measures, a preliminary concept for the implicit determination of component temperatures using integrated sensor systems on the handling system is presented.
KW - cup backward extrusion
KW - finite element simulations
KW - handling
KW - rotary friction welding
KW - tailored forming
UR - http://www.scopus.com/inward/record.url?scp=85214824410&partnerID=8YFLogxK
U2 - 10.1002/adem.202402031
DO - 10.1002/adem.202402031
M3 - Article
AN - SCOPUS:85214824410
JO - Advanced engineering materials
JF - Advanced engineering materials
SN - 1438-1656
ER -