The production of complex multi-functional, high-strength parts is becoming increasingly important in the industry. Especially with small batch size, the incremental flow forming processes can be advantageous. The production of parts with complex geometry and locally graded material properties currently depicts a great challenge in the flow forming process. At this point, the usage of closed-loop control for the shape and properties could be a feasible new solution. The overall aim in this project is to establish an intelligent closed-loop control system for the wall thickness as well as the α’-martensite content of AISI 304L-workpieces in a flow forming process. To reach this goal, a novel sensor concept for online measurements of the wall thickness reduction and the martensite content during forming process is proposed. It includes the setup of a modified flow forming machine and the integration of the sensor system in the machine control. Additionally, a simulation model for the flow forming process is presented which describes the forming process with regard to the plastic workpiece deformation, the induced α’-martensite fraction, and the sensor behavior. This model was used for designing a closed-loop process control of the wall thickness reduction that was subsequently realized at the real plant including online measured feedback from the sensor system.

This study illustrates the sensitivity of Barkhausen noise and eddy current based sensors to monitor the evolution of micromagnetic properties during phase transformation due to plastic deformation of metastable austenitic steel AISI 304L. The phase transformation was carried out on flow formed tubes, under specific thermomechanical conditions to produce local graded areas. The results show a very good potential of both types of sensors to monitor the evolution of magnetic properties during the production process in order to use those signals in closed-loop property-control systems.

This paper evaluates the suitability of the X-ray diffraction (XRD) technique to characterize the phase transformation during the metal forming of the metastable austenitic steel AISI 304L. Due to plastic deformation, phase transformation from γ-austenite into α’-martensite occurs. The XRD peaks at specific 2θ diffraction angles give information about the phase amount. Analyses of the results with different characterization techniques such as microscopic analysis, including electron backscatter diffraction (EBSD), macro- and microhardness tests and magneto-inductive measurements of α’-martensite, were carried out. A qualitative and quantitative correlation to compute the amount of α’-martensite from the XRD measurements was deduced. XRD was validated as a suitable technique to characterize the phase transformation of metastable austenites. Additional data could provide necessary information to develop a more reliable model to perform a quantitative analysis of the phases from XRD measurements.

Zusammenfassung Aufgrund aktueller Transformationsprozesse kommt der automatisierten und ressourceneffizienten Fertigung hochfester Leichtbauteile eine steigende Bedeutung zu, beispielsweise im Flugzeug- und Fahrzeugbau. Für kleine Losgrößen bietet sich hier insbesondere das Fertigungsverfahren des Drückwalzens an. Der konventionelle, industriell genutzte Drückwalzprozess stößt allerdings aufgrund der Prozesskomplexität hinsichtlich der Reproduzierbarkeit an seine Grenzen. Dies wird in der Praxis teilweise durch personengebundenes Erfahrungswissen kompensiert. Auch ist es nicht möglich, Bauteileigenschaften definiert einzustellen. Aus diesem Grund bietet der Einsatz einer neuartigen Eigenschaftsregelung Chancen zur Weiterentwicklung des Fertigungsprozesses und die Möglichkeit zur Prozessautomatisierung. Hier werden die Werkzeugbahnen abhängig einer Online-Eigenschaftsmessung über eine zusätzliche Reglerkaskade manipuliert. Die Entwicklung einer solchen Eigenschaftsregelung erfordert den Einsatz geeigneter, modellbasierter Entwurfsmethoden. In diesem Beitrag wird daher ein regelungstechnisches Systemmodell für das Drückwalzen metastabiler austenitischer Edelstähle vorgestellt. Das Simulationsmodell weist aufgrund seiner Echtzeitfähigkeit neben dem Einsatz als reines Entwurfsmodell weitere Nutzungsmöglichkeiten z.B. in Beobachtern auf und grenzt sich somit von domänenspezifischen Simulationstools wie der FEM ab.

This paper presents the characterization of the microstructure evolution during flow forming of austenitic stainless steel AISI 304L. Due to plastic deformation of metastable austenitic steel, phase transformation from γ-austenite into α’-martensite occurs. This is initiated by the formation of shear bands as product of the external stresses. By means of coupled microscopic and micromagnetic investigations, a characterization of the microstructure was carried out. In particular, this study shows the distribution of the strain-induced α’-martensite and its influence on material properties like hardness at different depths. The microstructural analyses by means of electron backscattered diffraction (EBSD) technique, evidence a higher amount of α’-martensite (ca. 23 %) close to the outer specimen surface, where the plastic deformation and the direct contact with the forming tool take place. In the middle area (ca. 1.5 mm depth from the outer surface), the portion of transformed α’-martensite drops to 7 % and in the inner surface to 2 %. These results are well correlated with microhardness and micromagnetic measurements at different depths. EBSD and atomic force microscopy (AFM) were used to make a detailed characterization of the topography and degree of deformation of the shear bands. Likewise, the mechanisms of nucleation of α’-martensite were discussed. This research contributes to the development of micromagnetic sensors to monitor the evolution of properties during flow forming. This makes them more suitable for closed-loop property control, which offers possibilities for an application-oriented and more efficient production.