Influence of different alloying elements on the intermetallic phase seam thickness of compound forged steel-aluminum parts

Behrens, Bernd‐Arno; Kosch, Klaus-Georg

doi:10.1007/s11740-011-0327-9

Cited by 12 publications

(4 citation statements)

References 6 publications

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“…The formation of these phases starts above the recrystallization temperature of aluminum at approximately 350 °C to 400 °C. In this context, FeAl 3 phase occurs in the temperature range between 350 °C and 500 °C [ 30 ]. The formation of a Fe 2 Al 5 phase takes place at temperatures above 500 °C, whereas it can be partially transformed to FeAl 3 during cooling [ 28 ].…”

Section: Resultsmentioning

confidence: 99%

“…High-aluminum intermetallic phases such as Fe 2 Al 5 and FeAl 3 are typical for joining processes with a short-time heat effect (e.g., compound forging) [29]. The formation of these phases starts above the recrystallization temperature of aluminum at approximately 350 • C to 400 • C. In this context, FeAl 3 phase occurs in the temperature range between 350 • C and 500 • C [30]. The formation of a Fe 2 Al 5 phase takes place at temperatures above 500 • C, whereas it can be partially transformed to FeAl 3 during cooling [28].…”

Section: For Peer Reviewmentioning

confidence: 99%

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Challenges in the Forging of Steel-Aluminum Bearing Bushings

et al. 2021

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The current study introduces a method for manufacturing steel–aluminum bearing bushings by compound forging. To study the process, cylindrical bimetal workpieces consisting of steel AISI 4820 (1.7147, 20MnCr5) in the internal diameter and aluminum 6082 (3.2315, AlSi1MgMn) in the external diameter were used. The forming of compounds consisting of dissimilar materials is challenging due to their different thermophysical and mechanical properties. The specific heating concept discussed in this article was developed in order to achieve sufficient formability for both materials simultaneously. By means of tailored heating, the bimetal workpieces were successfully formed to a bearing bushing geometry using two different strategies with different heating durations. A metallurgical bond without any forging defects, e.g., gaps and cracks, was observed in areas of high deformation. The steel–aluminum interface was subsequently examined by optical microscopy, scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). It was found that the examined forming process, which utilized steel–aluminum workpieces having no metallurgical bond prior to forming, led to the formation of insular intermetallic phases along the joining zone with a maximum thickness of approximately 5–7 µm. The results of the EDS analysis indicated a prevailing FexAly phase in the resulting intermetallic layer.

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Section: Resultsmentioning

confidence: 99%

Section: For Peer Reviewmentioning

confidence: 99%

Challenges in the Forging of Steel-Aluminum Bearing Bushings

et al. 2021

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“…A further approach is compound forging. In this process, hot forming is used to create form, force and/or metallic continuity joints [27][28][29][30][31]. The joining partners are not converted into molten state during the process, and only a slight formation of intermetallic Fe-Al phases occurs.…”

Section: Introductionmentioning

confidence: 99%

Characterization of Influences of Steel-Aluminum Dissimilar Joints with Intermediate Zinc Layer

Bick

Heuler

Treutler

et al. 2020

Metals

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Brittle intermetallic phases are formed when steel and aluminum are joined. Therefore, it is difficult to use this combination of materials when applying the multimaterial design in the construction of load-adapted and weight-adapted structures. In order to largely avoid the formation of these brittle phases, joining processes based on diffusion processes, such as composite forging, depict a good solution approach. The materials are joined in a solid state. Furthermore, zinc additives are used to create the joint. Zinc forms a compound with both steel and aluminum without the formation of brittle phases. By combining the composite forging process with zinc additives, strength values of 26 N/mm2 can be reached. This is higher, in comparison to former investigations of resistance spot welded and clinched joints. The joint properties depend on the composition of the zinc interlayer. Small amounts of magnesium in the zinc interlayer affected the strength and ductility values. While the strength decreased by about 30% in contrast to the zinc layer without magnesium, the ductility increased by 60%. This effect was probably due to the metallurgical impact of the alloying elements on phase formation, as could be shown by energy dispersive X-ray spectroscopy (EDX) analyses of the joint zones. Thereby, it was shown that the brittle intermetallic phases are located only in small areas.

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“…A new approach is therefore the creation of a material joint by composite forging of aluminum and steel with a zinc interlayer. In the case of composite forging, form-fitting, forcefitting, and/or material-locking connections are produced by hot forming [17][18][19][20][21]. While joining, the materials are not transferred to the molten state during forming under heat.…”

Section: Introductionmentioning

confidence: 99%

Soldering of steel sheets and zinc-coated aluminum by hybrid composite forging

2020

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In lightweight construction, light metals like aluminum are used in addition to high-strength steels. However, a welded joint of aluminum and steel leads to the precipitation of brittle, intermetallic phases and contact corrosion. Nevertheless, to use the advantages of this combination in terms of weight saving, composite hybrid forging has been developed. In this process, an aluminum solid part and a steel sheet were formed in a single step and joined at the same time with zinc as brazing material. For this purpose, the zinc was applied by hot dipping on the aluminum in order to produce a Brazing via these layers in a forming process, under pressure and heat. Due to the formed intermediate layer of zinc, the formation of the Fe-Al intermetallic phases and the contact corrosion are excluded. By determining the mathematical relationships between joining parameters and the mechanical properties of the joint, the strength of a specific joint geometry could be adjusted to reach the level of conventional joining techniques. In addition to the presentation of the joint properties, the influence of the joining process on the structure of the involved materials will be shown. Furthermore, the failure behavior under static tensile and shear stress will be shown.

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Influence of different alloying elements on the intermetallic phase seam thickness of compound forged steel-aluminum parts

Cited by 12 publications

References 6 publications

Challenges in the Forging of Steel-Aluminum Bearing Bushings

Challenges in the Forging of Steel-Aluminum Bearing Bushings

Characterization of Influences of Steel-Aluminum Dissimilar Joints with Intermediate Zinc Layer

Soldering of steel sheets and zinc-coated aluminum by hybrid composite forging

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