Investigation of the coating thickness of plasma-transferred arc deposition welded and cross wedge rolled hybrid parts

Blohm, Thoms; Mildebrath, Maximilian; Stonis, Malte; Langner, Jan; Hassel, Thomas; Behrens, Bernd‐Arno

doi:10.1007/s11740-017-0734-7

Cited by 23 publications

(14 citation statements)

References 18 publications

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“…2 within the welded casing and prevailing compressive stress states, which a typically for closed die hot forging processes [21], contribute to an intensive dynamic recrystallization and pore healing of the coarse welding microstructure. The positive influence of forming has already been demonstrated in previous studies on hybrid blanks in cross wedge rolling [22,23].…”

Section: Deposition Weldingsupporting

confidence: 53%

Manufacturing of High-Performance Bi-Metal Bevel Gears by Combined Deposition Welding and Forging

Chugreeva

Mildebrath

Diefenbach

et al. 2018

Metals

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The present paper describes a new method concerning the production of hybrid bevel gears using the Tailored Forming technology. The main idea of the Tailored Forming involves the creation of bi-metal workpieces using a joining process prior to the forming step and targeted treatment of the resulting joint by thermo-mechanical processing during the subsequent forming at elevated temperatures. This improves the mechanical and geometrical properties of the joining zone. The aim is to produce components with a hybrid material system, where the high-quality and expensive material is located in highly stressed areas only. When used appropriately, it is possible to reduce costs by using fewer high-performance materials than in a component made of a single material. There is also the opportunity to significantly increase performance by combining special load-tailored high-performance materials. The core of the technology consists in the material-locking coating of semi-finished parts by means of plasma-transferred-arc welding (PTA) and subsequent forming. In the presented investigations, steel cylinders made of C22.8 are first coated with the higher-quality heat-treatable steel 41Cr4 using PTA-welding and then hot-formed in a forging process. It could be shown that the applied coating can be formed successfully by hot forging processes without suffering any damage or defects and that the previous weld structure is completely transformed into a homogeneous forming-typical structure. Thus, negative thermal influences of the welding process on the microstructure are completely neutralized.

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Section: Deposition Weldingsupporting

confidence: 53%

Manufacturing of High-Performance Bi-Metal Bevel Gears by Combined Deposition Welding and Forging

Chugreeva

Mildebrath

Diefenbach

et al. 2018

Metals

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“…By applying further improved alloys as deposition material, it is expected to enhance the bearing fatigue life, although the primary goal is to provide a process to achieve machine elements where tailored properties are integrated by using the right material on discrete machine zones according to the demands. This process can be applied also on radial bearings by applying PTA with a subsequent cross-wedge rolling process (i.e., [2,23]). This enables them to be used as bearings under typical loads.…”

Section: Discussionmentioning

confidence: 99%

“…In the further course of the process chain, additional processing steps, such as heat treatment and machining (Figure 1c), are carried out until the finished hybrid component is completed (Figure 1d). Blohm et al [2] formed shafts of low-alloyed steel in a cross-wedge rolling process, which were beforehand cladded with heat-treated steel by PTA welding. It turned out that no defects occurred in Blohm et al [2] formed shafts of low-alloyed steel in a cross-wedge rolling process, which were beforehand cladded with heat-treated steel by PTA welding.…”

Section: Process Chain For the Manufacture Of A Hybrid Axial Bearing mentioning

confidence: 99%

“…Blohm et al [2] formed shafts of low-alloyed steel in a cross-wedge rolling process, which were beforehand cladded with heat-treated steel by PTA welding. It turned out that no defects occurred in Blohm et al [2] formed shafts of low-alloyed steel in a cross-wedge rolling process, which were beforehand cladded with heat-treated steel by PTA welding. It turned out that no defects occurred in the joint.…”

Section: Process Chain For the Manufacture Of A Hybrid Axial Bearing mentioning

confidence: 99%

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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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“…As regards other research works investigating the possibilities of increasing the technological potential of CWR, a study on the forming of parts from cylindrical billets produced by plasma-transferred arc (PTA) welding [22] and a study on the manufacturing of microparts for electronics are worth mentioning. The results of the latter were reported by, among others, Wei et al [23] and Jiang et al [24] who found that CWR is an effective cold forming process for producing copper parts with a diameter smaller than 1 mm, characterized by high-strength properties.…”

Section: Introductionmentioning

confidence: 99%

Cavity formation in cross-wedge rolling processes

Pater

Tomczak

Bulzak

2018

J. Iron Steel Res. Int.

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The problem of end-face cavity formation in parts produced by cross-wedge rolling was studied in order to reduce material consumption. The cavity depth was measured by the displacement method. Twenty-one different cases of rolling were analysed by finite element method to determine the effects of process parameters such as the wedge tool angle, the temperature of material, the tool velocity and the reduction ratio on the depth of end-face cavities. Relationships between these parameters are examined in order to establish dependencies enabling quick and simple selection of a concavity allowance in order to remove the cavities. The equations for calculating the concavity allowance were verified in an experimental process for manufacturing ball pins with the use of flat tools. Rolling tests were performed using a billet with its length selected in compliance with the established dependencies. The experimental results demonstrate that the proposed solution is a viable method for end-face cavity removal.

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Investigation of the coating thickness of plasma-transferred arc deposition welded and cross wedge rolled hybrid parts

Cited by 23 publications

References 18 publications

Manufacturing of High-Performance Bi-Metal Bevel Gears by Combined Deposition Welding and Forging

Manufacturing of High-Performance Bi-Metal Bevel Gears by Combined Deposition Welding and Forging

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

Cavity formation in cross-wedge rolling processes

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