Enhanced Performance of Steel-Aluminium Cast Nodes through Cold Metal Transfer

Ucsnik, Stephan; Gradinger, Rudolf; Bećirović, Almedin; Waldhör, Andreas

doi:10.4028/www.scientific.net/msf.765.736

Cited by 5 publications

(2 citation statements)

References 0 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Ucsnik et al studied the effect of different pin geometries on the mechanical behavior of DA hybrid joints. In their work, ball‐head and cylindrical pins were welded by CMT onto stainless steel substrates, and VARI was used to assemble the CFPR (epoxy matrix).…”

Section: Mechanical Performance Of Da Of Metal–composite Hybrid Jointsmentioning

confidence: 99%

A review on direct assembly of through‐the‐thickness reinforced metal–polymer composite hybrid structures

Feistauer

Santos

Amancio‐Filho

2018

Polymer Engineering & Sci

View full text Add to dashboard Cite

Constant efforts to reduce the structural weight of transportation systems as a solution to control emission levels are currently shaping the way modern cars and airplanes are designed and manufactured. Increased attention has been given to innovative metal–composites multi‐material concepts for the production of lightweight structures. However, the nature of these very dissimilar materials makes their joining a rather complicated task. Recently several technologies have been proposed to overcome process limitation and increase the load transfer between metal and composite in hybrid structures. One of the promising solutions is a new concept known as direct assembling with through‐the‐thickness reinforcements. In this concept, the composite material of a hybrid joint is directly assembled upon a surface‐structured metallic part. Features structured on the metallic part, by a manufacturing phase, act as a through‐the‐thickness reinforcement improving the out‐of‐plane strength and load transfer capabilities of such joints. The current status and state‐of‐art direct assembling technologies are reviewed in this article. Examples of reviewed metal structuring techniques include micromachining, stamping, Surfi‐Sculpt, additive manufacturing, cold metal transfer, and metal injection molding structuring. Direct assembling techniques addressed in this article are vacuum‐assisted resin infusion, resin transfer molding, prepreg/autoclave assembly, and ultrasonic joining. POLYM. ENG. SCI., 59:661–674, 2019. © 2018 The Authors. Polymer Engineering & Science published by Wiley Periodicals, Inc. on behalf of Society of Plastics Engineers.

show abstract

Section: Mechanical Performance Of Da Of Metal–composite Hybrid Jointsmentioning

confidence: 99%

A review on direct assembly of through‐the‐thickness reinforced metal–polymer composite hybrid structures

Feistauer

Santos

Amancio‐Filho

2018

Polymer Engineering & Sci

View full text Add to dashboard Cite

show abstract

“…An interlocking Al-Al compound has been developed by Rübner et al [4], where a meshed sheet is surrounded by die-cast. Ucsnik et al [8] improved the axial and rotational strength between two steel sleeves by pins welded on the steel surface and surrounded by Al-cast. A beam structure for automotive application was realized by Pasligh [9] via reinforcing a sheet metal by X-shaped light metal cast structures.…”

Section: State-of-the-artmentioning

confidence: 99%

Optimization of the Surface Geometry in Structured Cold Rolling for Interlocking of Formed and Die-Cast Metal Components

Ringel

Lohmar

2022

DDF

View full text Add to dashboard Cite

Modern lightweight design is often based on multi-material components. For example, structured sheet metals can be equipped with a die-cast light metal insert for structural support. To interlock sheet and insert, structures with undercuts are formed into the sheet in a multi-pass rolling process. In a first pass, structured rolls are used to create a structure of channels and ribs. Undercuts are formed in a consecutive pass by flat rolling those ribs. During die-casting, the melt flows into the channels and forms an interlocking connection once solidified. The joint strength is decisively determined by the undercut geometry. The undercuts formed by material displacement increase with the height reduction in the flat rolling pass. However, after a certain amount of material displacement, the channel side edge starts to fold over the channel bottom and forms an inner notch. Those inner notches can be prone to crack initiation and subsequently lead to component failure. To analyze the surface structure regarding channel depth, undercuts and inner notches as well as finally maximize the joint strength, a combined experimental and numerical study was laid out. The surface of 2.0 mm DC04 was structured with up to 0.5 mm deep channels and then flattened with different height reductions. The results from the 2D explicit FE-model suggest that a process optimum for those surface structures with high undercut width but without inner notch exists at 14% height reduction. However, in the experiments inner notches started to form at approx. 8% height reduction with approx. 20 µm wide undercuts for the given experimental setup. In contrast, maximum undercuts of approx. 50 µm form at 26% height reduction, but also cause inner notches with approx. 60 µm length.

show abstract

Investigation of the Compound Strength of Hybrid Casting Components with Different Variations of Coated and Undercut Sheet Metal

Bruckmeier,

Ringel,

Erck

et al. 2024

Inter Metalcast

View full text Add to dashboard Cite

Lightweight design can reduce CO2 emissions and improve energy efficiency, especially in the fuel-intensive transportation sector. Multi-material design approaches can combine specific properties of materials for effective lightweight design. A multi-material component made from two metals used widely in industry could combine the exceptionally lightweight properties of aluminum with the strength and structural integrity of steel. However, joining aluminum and steel is a challenge due to their different thermo-physical properties and the possible formation of brittle intermetallic phases. In hybrid casting, aluminum is cast around a steel sheet insert in a high-pressure die casting process to produce complex parts. In a first approach, a cold gas sprayed aluminum coating on the insert was tested as a bonding agent between the steel substrate and the molten aluminum. The joint was achieved by a combination of metallurgical bonding and micro-clamping. As a second option, surface structures with undercuts were applied to the steel sheet by modified cold rolling, which allowed the molten aluminum to flow into the channels and interlock with the solid steel. Different orientations of the structure on the insert were tested. In addition, the combination of both approaches was used to potentially enhance the positive effect of the pretreatment techniques. Given the critical importance of joint strength, the quality of these approaches was tested by static tensile tests and dynamic fatigue tests. The results show that the joint by coatings is strongly influenced by the process temperature. The improvement of the joint by the surface structure depends on its orientation to the melt flow.

show abstract

Enhanced Performance of Steel-Aluminium Cast Nodes through Cold Metal Transfer

Cited by 5 publications

References 0 publications

A review on direct assembly of through‐the‐thickness reinforced metal–polymer composite hybrid structures

A review on direct assembly of through‐the‐thickness reinforced metal–polymer composite hybrid structures

Optimization of the Surface Geometry in Structured Cold Rolling for Interlocking of Formed and Die-Cast Metal Components

Investigation of the Compound Strength of Hybrid Casting Components with Different Variations of Coated and Undercut Sheet Metal

Contact Info

Product

Resources

About