Investigation on a new process chain of deposition or friction welding and subsequent hot forging

Abstract

According to the state of the art most current forging parts and technical components are made of mono-materials. Nevertheless, parts consisting of only one material increasingly reach their specific material and constructive limits in the established production processes. Through use of previously joined raw parts consisting of different materials, it is possible to produce application-optimized hybrid parts. This paper describes the production chain of hybrid parts produced by combining two different joining processes with subsequent hot compression tests. The joining of various materials is realized by a deposition welding with a laser-stabilized gas-metalarc deposition welding (LGD) process and a conventional friction welding process. Subsequently, the hybrid samples are compressed under varying forming parameters such as temperature and deformation degrees. In order to characterize the joining zone, metallurgical investigations are carried out.

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

“…After welding, the component cools down faster due to self-quenching, which leads to a higher hardness, especially in the outer area. In comparison with previous studies focused on the upsetting of bi-metal pre-forms [13,18,19], the current study represents a successful implementation of bi-metal forming in context of complex In comparison with previous studies focused on the upsetting of bi-metal pre-forms [13,18,19], the current study represents a successful implementation of bi-metal forming in context of complex geared geometry in a single step. The forged parts demonstrate an appropriate mould filling; neither surface defects nor micro-cracks have been detected in the interface zone or in the deposited layer.…”

“…After welding, the component cools down faster due to self-quenching, which leads to a higher hardness, especially in the outer area. In comparison with previous studies focused on the upsetting of bi-metal pre-forms [13,18,19], the current study represents a successful implementation of bi-metal forming in context of complex In addition, the hardness profiles were examined from the sample edge in radial direction to the middle in both, deposition-welded workpieces and forged bevel gears (Figure 7). The measurement lines are respectively marked with white arrows in Figure 6.…”

“…Domblesky et al investigated hot compression tests in order to study the forgeability of friction-welded bi-metal pre-forms combining copper, aluminium and steel [17]. Frischkorn et al examined the hot forging behaviour of further material combinations comprising steel, aluminium, titanium and Inconel [18]. Wang et al conducted numerical and experimental investigations on the hot upsetting of bi-metal billets produced by weld cladding (C15/316L) [19].…”

Simulation Assisted Process Development for Tailored Forming

“…The flow behaviour of similar material combination (e.g., carbon steel-stainless steel) was found to be comparable; whereas with dissimilar material combination (e.g., carbon steel-copper), plastic deformation occurred mainly in the material with lower strength. Frischkorn et al investigated hot forging of deposition-welded and friction-welded bi-material workpieces by using a forming simulator [9]. In a follow-up study, Behrens et al applied cross wedge rolling as forming process [10].…”