Apart from reducing the processing energy, hardening and tempering of near-net shape forged components from their forging heat primarily promises shortened conventional process sequences. In this case, the continuous cooling transformation diagrams (CCT diagrams) found in the literature can only be used as a rough approximation of microstructural transformations during the heat-treatment. The reasons for this are that firstly, the deformation influences the transformation kinetics and secondly, the deformation temperatures are comparatively high. Therefore, both deformation CCT diagrams and, for reference purposes, CCT diagrams without deformation were determined for a selection of heattreatable steels (34CrMo4, 42CrMo4, 52CrMo4, 51CrV4, 34NiMo6) at the heating temperature of 1200 8C and deformation levels of 0.3 and 0.6.

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As a rule, induction surface hardening is carried out industrially by employing polymer solutions since these ensure a more homogeneous quench than immersion cooling in water. Besides reproducing the quenching process, the intention here is to minimise the hardening defects and the distortions arising from the heat treatment. Polymer solutions also have a few disadvantages which include, among others, poor environmental compatibility and handleability. Quenching by means of spray cooling provides an effective alternative. The purpose of the current investigation is to substitute the polymer solution by a water‐air spray in induction hardening equipment for surface hardening spur gearwheels made of 42CrMo4 hardening and tempering steel. The suitability of spray cooling was assessed by means of hardness measurements, residual stress conditions, distortion measurements and by metallographic examinations. Based on the analyses currently carried out, it was possible to show that the two‐phase spray cooling represents an alternative quenching method which produces comparable component properties.

Novel aluminum-copper compound castings devoid of oxide layers at the interface between the joining partners were developed in order to increase the thermal conductivity of the hybrid component. Due to the natural oxide layers of both aluminum and copper, metallurgical bonds between such bi-metal castings cannot be easily achieved in conventional processes. However, in an atmosphere comparable to extreme high vacuum created by using silane-doped inert gas, metallurgical bonds between the active surfaces of both aluminum and copper can be realized without additional coatings or fluxes. An intermetallic was created between aluminum and copper. Thus, very high thermal conductivities could be obtained for these hybrid castings, exceeding those of conventionally joined samples considerably. The intermetallic phase seams emerging between the joining partners were investigated using scanning electron microscopy and X-ray diffraction. The reduction of casting temperatures resulted in narrower intermetallic phase seams and these in turn in a much lower contact resistance between the two joining partners. This effect can be utilized for increasing the heat transfer capabilities of compound casting components employed for cooling heat sources such as high-power light-emitting diodes.

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