The process‐chain of highly stressed parts incorporates among others casting, forming, and heat treatment. Segregations are always found within these parts. Segregations and its consequences are only understandable by considering the whole process‐chain. In this paper, segregations within the hot rolled bar and after cold forging to bevel gears are analyzed metallographically. Dilatometer specimens are used for analyzing the phase transformation behavior from different segregation structures within the hot rolled bar. The deformation during forming and the influence on the microstructure after heat treatment is discussed. A coupled forming‐heat treatment simulation is presented based on the experimental findings. The deformation of the macro‐segregation is calculated by a forming simulation. A phase transformation model depending on the macro‐segregation is used for calculation of the microstructure after heat treatment. The final microstructure and hardness distribution of formed parts is calculated and discussed in comparison with the experimental results.

In recent years, magnetocaloric materials have been extensively studied as materials for use in alternative cooling systems. Shaping the magnetocaloric material to thin-walled heat exchanger structures is an important step to achieve efficient magnetocaloric cooling systems. In the present work, experimental investigations were carried out on the heat treatment of LaFe11.4Si1.2Co0.4 alloy processed by Laser Beam Melting (LBM) technology. Due to the rapid solidification after melting, LBM results in a refined micro structure, which requires much shorter heat treatment to achieve a high percentage of magnetocaloric 1:13 phase compared to conventional cast material. The influence of the heat treatment parameters (temperature, time, and cooling rate) on the resulting microstructure has been extensively studied. In addition to the conventional heat treatment process, induction technology was investigated and the results were very promising in terms of achieving good magnetocaloric properties after short-time annealing. After only 15 min holding time at 1373 K, the magnetic entropy change (∆S) of -7.9 J/kg/K (0–2 T) was achieved.

A change in component design could help achieve objectives in lightweight construction. However, lightweight component design can incur serious distortion problems after the final heat treatment due to reduced stiffness or asymmetries in the mass distribution. The analysis of design modification through geometrical variations and their consequences on the distortion behavior through experiments can be costly and time consuming. In this paper, using 3D simulation models, different modified lightweight geometries are simulated. Using these simulation results, the authors try to understand the complex distortion behavior and correlate it with the effects of design modification.

On the basis of economic and ecological constraints a reduced weight and/or minimized volume of automobile components is more and more focused in industrial and scientific activities in recent years. Apart from the application of new materials with considerably lower density a change of component design can be used to succeed in aims regarding lightweight construction. But aspects of a production-oriented design, especially for heat treated drive train components, have to be considered, too. This topic applies in particular to the final heat treatment because serious distortion problems can arise due to reduced stiffness and asymmetric mass distribution of a component. In the previous research work, the distortion behavior of gear base bodies as essential part of a gear was analyzed and a first design guideline for gear base bodies resulting in tolerable distortion was developed. In the ongoing research work, the basic approaches used for the determination of this guideline for gear base bodies will be applied to a complex gear with strong asymmetric mass distribution. One of the first questions of this work concerns the influence of the teeth on base body distortion. In this paper results of comparitive experiments between a complexed shaped gear with and without teeth will be presented.

Objectives in the field of lightweight construction can be achieved by changing the component design, among other things. However, a design suitable for production would have to be taken into account, since serious distortion problems can occur after the final heat treatment due to reduced stiffness or asymmetries in the mass distribution. To illustrate this problem area, case hardening experiments using the example of a weight-reduced counter gear made of 20MnCr5 were carried out and have shown significantly different distortion behavior depending on the geometry and process parameters. However, it is difficult or even impossible to understand such a distortion behavior only through experiments, since many different variables can be responsible for dimensional and shape changes. In this context, a simulation tool can be very helpful to identify important variables that cause dimensional and shape changes and to understand the associated processes. This paper attempts to answer some open questions that arise from experiments on distortion behavior through simulations. ◼