Compound Forging of Hybrid Powder-Solid-Parts Made of Steel and Aluminum

Abstract

Compound forging is a technology to successfully manufacture hybrid parts by applying resource-saving process steps. During compound forging of steel-aluminum parts the formation of intermetallic phases is benefited. The thickness of these intermetallic phases influences the bonding and thus the global part quality. According to literature, specific coating elements reduce the phase seam thickness. In powder-metallurgically manufactured parts it is possible to selectively insert specific elements in the surface area. Therefore, a time intensive coating process can be avoided. The applicability of combining the technologies of powder-metallurgy and compound forging is discussed in this paper. Powder-metallurgically manufactured and solid parts made of steel and aluminum are compound forged and the influences on deformation behavior and the joining zone are investigated.

Review of recent developments in manufacturing lightweight multi-metal gears

“…Groche et al [60] proposed the possibility of an additively manufactured outer layer which could be extended to the application of interlayer materials. Thusfar, multi-metal studies have focused on a solid inner material with an additively manufactured powder outer layer [20,143]. However, it may be possible to additively manufacture a coating in a vacuum onto workpieces with high oxidising potential such as steels in order to also prevent oxidation during subsequent forging.…”

Process Chain for the Production of a Bimetal Component from Mg with a Complete Al Cladding

“…Li et al produced Al-Mg-Al sheets by hot roll bonding, and investigated the deep drawability [17]. Other investigations have focused on the forging of powder composites [18,19] or metal matrix composites with different particle reinforcement [20,21]. Foydl et al investigated steel-reinforced aluminum.…”

Temperature Influence on Bond Formation in Multi-material Joining by Forging

“…However, if the bonding surfaces are covered by largely distributed oxide layers as also reported in [9] or if the increased interface temperature leads to a critical formation of thick intermetallic phases as investigated in the case of lateral extrusion of aluminum and magnesium in [10], the bond strength can be affected negatively. Behrens et al [11] investigated hot forging of aluminum and steel compounds at a starting temperature of ~ 970 °C and ~ 520 °C for steel and aluminum, respectively. In this case, intermetallic phases (~ 4 μm) are built up at the weld interface.…”