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With the aid of multiple wire drawing passes, the magnesium alloys ZEK100, MgCa0.8, and AL36 were reduced to monofilament wires possessing diameters between 0.5 and 0.1 mm. These filaments were subsequently twisted into poly‐filament suture material using stranding. In order to analyze the microstructural constituents and the mechanical‐tribological properties, metallographic specimens were prepared and tensile tests were performed on both monofilament as well as poly‐filament wire strands. Appropriate parameters were ascertained for the wire drawing process with regard to forming rate, temperature, and heat treatment. During the investigations, the alloy ZEK100 exhibited particularly interesting mechanical properties which, owing to its high tensile strengths (up to 550 MPa for monofilament) and fracture strains (up to 30% for poly‐filament), are comparable to those of conventional polymer‐based suture materials. In addition to this, integrating a core (internal, individual wire) into the poly‐filament mesh of wire strands represents an interesting alternative for future research in which structures composed of different materials, and the advantages of combining their properties are brought into particular focus.

A novel co-extrusion process for the production of coaxially reinforced hollow profiles has been developed. Using this process, hybrid hollow profiles made of the aluminum alloy EN AW-6082 and the case-hardening steel 20MnCr5 (AISI 5120) were produced, which can be forged into hybrid bearing bushings by subsequent die forging. For the purpose of co-extrusion, a modular tooling concept was developed where steel tubes made of 20MnCr5 are fed laterally into the tool. This LACE (lateral angular co-extrusion) process allows for a variation of the volume fraction of the reinforcement by using steel tubes with different wall thicknesses, which enabled the production of compound profiles having reinforcement contents of either 14 vol.% or 34 vol.%. The shear strength of the bonding area of these samples was determined in push-out tests. Additionally, mechanical testing of segments of the hybrid profiles using shear compression tests was employed to provide information about the influence of different bonding mechanisms on the strength of the composite zone.

Novel aluminum-copper compound castings devoid of oxide layers at the interface between the joining partners were developed in order to increase the thermal conductivity of the hybrid component. Due to the natural oxide layers of both aluminum and copper, metallurgical bonds between such bi-metal castings cannot be easily achieved in conventional processes. However, in an atmosphere comparable to extreme high vacuum created by using silane-doped inert gas, metallurgical bonds between the active surfaces of both aluminum and copper can be realized without additional coatings or fluxes. An intermetallic was created between aluminum and copper. Thus, very high thermal conductivities could be obtained for these hybrid castings, exceeding those of conventionally joined samples considerably. The intermetallic phase seams emerging between the joining partners were investigated using scanning electron microscopy and X-ray diffraction. The reduction of casting temperatures resulted in narrower intermetallic phase seams and these in turn in a much lower contact resistance between the two joining partners. This effect can be utilized for increasing the heat transfer capabilities of compound casting components employed for cooling heat sources such as high-power light-emitting diodes.