Basic study on the process combination of deposition welding and subsequent hot bulk forming

Behrens, Bernd‐Arno; Overmeyer, Ludger; Barroi, Alexander; Frischkorn, Conrad; Hermsdorf, Jörg; Kaierle, Stefan; Stonis, Malte; Huskic, Aziz

doi:10.1007/s11740-013-0478-y

Cited by 29 publications

(19 citation statements)

References 11 publications

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“…Disadvantageous microstructure formations, which can have a negative effect compared to the later type of loading and which are caused by the heat influence of the welding process, are dissolved by the forming process. This effect can be explained by thermal, mechanical and thermomechanical treatment during the warm forming which leads to improved mechanical properties and component quality as shown in previous research works [20]. The semi-finished washers were austenitized in an electrically heated chamber furnace in neutral annealing coal and under argon atmosphere at 860 °C for 45 min.…”

Section: Metallographic Investigationsmentioning

confidence: 86%

Manufacturing and Evaluation of Multi-Material Axial-Bearing Washers by Tailored Forming

Behrens

Chugreev

Matthias

et al. 2019

Metals

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Components subject to rolling contact fatigue, such as gears and rolling bearings, are among the fundamental machine elements in mechanical and vehicle engineering. Rolling bearings are generally not designed to be fatigue-resistant, as the necessary oversizing is not technically and economically marketable. In order to improve the load-bearing capacity, resource efficiency and application possibilities of rolling bearings and other possible multi-material solid components, a new process chain was developed at Leibniz University Hannover as a part of the Collaborative Research Centre 1153 “Tailored Forming”. Semi-finished products, already joined before the forming process, are used here to allow a further optimisation of joint quality by forming and finishing. In this paper, a plasma-powder-deposition welding process is presented, which enables precise material deposition and control of the welding depth. For this study, bearing washers (serving as rolling bearing raceways) of a cylindrical roller thrust bearing, similar to type 81212 with a multi-layer structure, were manufactured. A previously non-weldable high-performance material, steel AISI 5140, was used as the cladding layer. Depending on the degree of forming, grain-refinement within the welded material was achieved by thermo-mechanical treatment of the joining zone during the forming process. This grain-refinements lead to an improvement of the mechanical properties and thus, to a higher lifetime for washers of an axial cylindrical roller bearing, which were examined as an exemplary component on a fatigue test bench. To evaluate the bearing washers, the results of the bearing tests were compared with industrial bearings and deposition welded axial-bearing washers without subsequent forming. In addition, the bearing washers were analysed micro-tribologically and by scanning acoustic microscopy both after welding and after the forming process. Nano-scratch tests were carried out on the bearing washers to analyse the layer properties. Together with the results of additional microscopic images of the surface and cross-sections, the causes of failure due to fatigue and wear were identified.

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Section: Metallographic Investigationsmentioning

confidence: 86%

Manufacturing and Evaluation of Multi-Material Axial-Bearing Washers by Tailored Forming

Behrens

Chugreev

Matthias

et al. 2019

Metals

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“…The semifinished part will then be formed by using a single forming tool to achieve the final contour. Behrens et al investigated deposited claddings on a shaft which was formed subsequently [8]. The hybrid part was made of a 42CrMo4 bar cladded with the high-alloyed steels 1.8401 and 1.4718.…”

Section: Introductionmentioning

confidence: 99%

Investigation of microstructure and hardness of a rib geometry produced by metal forming and wire-arc additive manufacturing

et al. 2018

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Within the scope of consumer-oriented production, individuality and cost-effectiveness are two essential aspects, which can barely be met by traditional manufacturing technologies. Conventional metal forming techniques are suitable for large batch sizes. If variants or individualized components have to be formed, the unit costs rise due to the inevitable tooling costs. For such applications, additive manufacturing (AM) processes, which do not require tooling, are more suitable. Due to the low production rates and limited build space of AM machines, the manufacturing costs are highly dependent on part size and batch size. Hence, a combination of both manufacturing technologies i.e. conventional metal forming and additive manufacturing seems expedient for a number of applications. The current study develops a process chain combining forming and additive manufacturing. First, a semi-finished product is formed with forming tools of reduced complexity and then finished by additive manufacturing. This research investigates the addition of features using AlSi12 created by Wire Arc Additive Manufacturing (WAAM) on formed EN-AW 6082 preforms. By forming, the strength of the material was increased, while this effect was partly reduced by the heat input of the WAAM process.

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“…Tailored forming involves deposition welding (see Sections 2.1-2.2) and subsequent forming (see Section 2.3) to produce multi-material solid components [10]. An exemplary component of this process chain is shown in Figure 1 (left).…”

Section: Tailored Forming Approachmentioning

confidence: 99%

Numerical Simulation and Experimental Validation of the Cladding Material Distribution of Hybrid Semi-Finished Products Produced by Deposition Welding and Cross-Wedge Rolling

Kruse

Mildebrath

Budde

et al. 2020

Metals

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The service life of rolling contacts is dependent on many factors. The choice of materials in particular has a major influence on when, for example, a ball bearing may fail. Within an exemplary process chain for the production of hybrid high-performance components through tailored forming, hybrid solid components made of at least two different steel alloys are investigated. The aim is to create parts that have improved properties compared to monolithic parts of the same geometry. In order to achieve this, several materials are joined prior to a forming operation. In this work, hybrid shafts created by either plasma (PTA) or laser metal deposition (LMD-W) welding are formed via cross-wedge rolling (CWR) to investigate the resulting thickness of the material deposited in the area of the bearing seat. Additionally, finite element analysis (FEA) simulations of the CWR process are compared with experimental CWR results to validate the coating thickness estimation done via simulation. This allows for more accurate predictions of the cladding material geometry after CWR, and the desired welding seam geometry can be selected by calculating the cladding thickness via CWR simulation.

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Basic study on the process combination of deposition welding and subsequent hot bulk forming

Cited by 29 publications

References 11 publications

Manufacturing and Evaluation of Multi-Material Axial-Bearing Washers by Tailored Forming

Manufacturing and Evaluation of Multi-Material Axial-Bearing Washers by Tailored Forming

Investigation of microstructure and hardness of a rib geometry produced by metal forming and wire-arc additive manufacturing

Numerical Simulation and Experimental Validation of the Cladding Material Distribution of Hybrid Semi-Finished Products Produced by Deposition Welding and Cross-Wedge Rolling

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