Investigation into the bond strength of the joining zone of compound forged hybrid aluminium-steel bearing bushing

Behrens, Bernd‐Arno; Sokolinskaja, Valeria; Chugreeva, Anna; Diefenbach, Julian; Thürer, Susanne Elisabeth; Bohr, Dieter

doi:10.1063/1.5112562

Cited by 5 publications

(5 citation statements)

References 8 publications

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“…Compared with the shear strengths achieved in push-out tests on compound forged bearing bushings investigated by Behrens et al [16], the shear strength achieved with semi-finished products manufactured by LACE was about 20 MPa lower. The bond formation in the compound forging was thus somewhat better, which can be substantiated by the joint forming, and thus by the more extensive formation of new surfaces in the process [14].…”

Section: Discussioncontrasting

confidence: 61%

“…In order to comply with the requirements of the intended subsequent die forging process, specifications for the compound profiles with regard to the internal geometry of the reinforcing element as well as the position of the joining partners in relation to each other were defined prior to toolset and process development. Thus, the co-extruded semi-finished products were required to have an internal diameter Ø i of 32 mm as well as an aluminum cladding with a uniform wall thickness so that the hybrid semi-finished products can be heated by means of an internal inductor prior to die-forging [16]. Furthermore, a maximum deviation in the coaxial arrangement of the joining partners of 0.2 mm (0.3%) was aimed for with a height of the semi-finished product of 85 mm.…”

Section: Discussionmentioning

confidence: 99%

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Lateral Angular Co-Extrusion: Geometrical and Mechanical Properties of Compound Profiles

Thürer

Peddinghaus

Heimes

et al. 2020

Metals

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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.

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Section: Discussioncontrasting

confidence: 61%

Section: Discussionmentioning

confidence: 99%

Lateral Angular Co-Extrusion: Geometrical and Mechanical Properties of Compound Profiles

Thürer

Peddinghaus

Heimes

et al. 2020

Metals

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“…Table 1 contains the corresponding chemical composition of the alloyed aluminium cores and the specific solidus-and liquidus temperature, which was calculated based on the state of the recent literature. An important criterion is to obtain an adequate forming result, specific heating strategies and an appropriate temperature gradient between steel and aluminium are needed, to adjust almost equal flow stresses [9]. This requires an inhomogeneous heating in which steel is heated to forming temperatures in a range between 900 -1,200 °C.…”

Section: Methodsmentioning

confidence: 99%

Analysis of alloy influence on THE JOINT FORMATION IN compound forging of geared steel-aluminium components

Behrens

Brunotte

Kuwert

2020

METAL 2020 Conference Proeedings

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In order to reduce CO2 emissions, lightweight constructions and the use of steel-aluminium components have become increasingly important in current product development. When manufacturing such components, the dissimilar chemical and physical properties of these materials lead to major challenges in terms of metallurgical bond formation during joining. In particular, chemical compositions have a major impact on the joint properties and have therefore already been intensively investigated in welding technology. With regard to forming technology, the issue arises whether these findings can be transferred to simultaneous forming and joining for the manufacturing of steel-aluminium components by compound forging. In the scope of this study, aluminium workpieces were therefore alloyed with defined amounts of common welding additives such as zinc, nickel and silicon using powder metallurgy. Subsequently, these workpieces were forged together with steel and subjected to metallographic examination. The studies show that compound forging of the used alloy configurations is basically possiblehowever, bond formation varies significantly with different chemical composition. Alloying with zinc and silicon results in a reduced liquidus temperature and consequently in melting. In contrast, alloying with nickel leads to an extended joining zone and benefits the maximal mechanical load capacity.

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“…4. The operating principle is described in detail in a previous publication [26]. Before the forming process, the lubricant Berulit 913 (Carl Bechem GmbH, Hagen, Germany) diluted with water in a ratio of 1:3 was applied to the semi-finished products.…”

Section: Die Forgingmentioning

confidence: 99%

Process chain for the manufacture of hybrid bearing bushings

Thürer

Chugreeva

Heimes

et al. 2021

Prod. Eng. Res. Devel.

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The current study presents a novel Tailored Forming process chain developed for the production of hybrid bearing bushings. In a first step, semi-finished products in the form of locally reinforced hollow profiles were produced using a new co-extrusion process. For this purpose, a modular tool concept was developed in which a steel tube made of a case-hardening steel, either C15 (AISI 1015) or 20MnCr5 (AISI 5120), is fed laterally into the tool. Inside the welding chamber, the steel tube is joined with the extruded aluminum alloy EN AW-6082. In the second step, sections from the compound profiles were formed into hybrid bearing bushings by die forging. In order to set the required forming temperatures for each material—aluminum and steel—simultaneously, a tailored heating strategy was developed, which enabled successful die forging of the hybrid workpiece to the desired bearing bushing geometry. Using either of the case-hardening steels in combination with aluminum, this novel process chain made it possible to produce intact hybrid bearing bushings, which showed both macroscopically and microscopically intimate material contact inside the compound zone.

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Investigation into the bond strength of the joining zone of compound forged hybrid aluminium-steel bearing bushing

Cited by 5 publications

References 8 publications

Lateral Angular Co-Extrusion: Geometrical and Mechanical Properties of Compound Profiles

Lateral Angular Co-Extrusion: Geometrical and Mechanical Properties of Compound Profiles

Analysis of alloy influence on THE JOINT FORMATION IN compound forging of geared steel-aluminium components

Process chain for the manufacture of hybrid bearing bushings

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