Co-extrusion of semi-finished aluminium-steel compounds

Thürer, Susanne Elisabeth; Uhe, Johanna; Golovko, O.; Bonk, Christian; Bouguecha, Anas; Klose, Christian; Behrens, Bernd‐Arno; Maier, Hans Jürgen

doi:10.1063/1.5008158

Cited by 13 publications

(12 citation statements)

References 8 publications

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“…An almost symmetric position of the weld seams was found for both ram speeds at the investigated location. It was shown previously in [2] that the weld seams were laterally displaced in the initial segment of the hybrid profile and that the displacement of the weld seams decreased during the extrusion process. Obviously, the steel reinforcement had not been positioned truly coaxially inside the profile in the shown cross-sections.…”

Section: Extrusion Experimentsmentioning

confidence: 71%

“…The experiments described in this study were carried out on a 2.5 MN extrusion press (Müller engineering GmbH, Todtenweis, Germany) shown in Figure 1a. The LACE process investigated for the production of aluminum-steel compound profiles with a steel rod as a coaxial reinforcing element was developed by Thürer et al [2]. The tool concept is presented in Figure 1b.…”

Section: Methodsmentioning

confidence: 99%

“…Within the Collaborative Research Centre 1153, a lateral angular co-extrusion (LACE) process of aluminum and steel was developed where a coaxial position of the steel rod within the matrix material was realized [2]. This development was based on the process proposed by Grittner et al and allowed the co-extrusion of the asymmetric compound profiles of aluminum and titanium using conventional aluminum billets.…”

Section: Introductionmentioning

confidence: 99%

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A Numerical Study on Co-Extrusion to Produce Coaxial Aluminum-Steel Compounds with Longitudinal Weld Seams

Behrens

Klose

Chugreev

et al. 2018

Metals

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The use of lightweight materials is one possibility to limit the weight of vehicles and to reduce CO2 emissions. However, the mechanical properties and weight-saving potential of mono-materials are limited. Material compounds can overcome this challenge by combining the advantages of different materials in one component. Lateral angular co-extrusion (LACE) allows the production of coaxial semi-finished products consisting of aluminum and steel. In this study, a finite element model of the LACE process was built up and validated by experimental investigations. A high degree of agreement between the calculated and experimentally determined forces, temperatures, and the geometrical shape of the hybrid profiles was achieved. In order to determine suitable parameters for further extrusion experiments, the influence of different process parameters on material flow and extrusion force was investigated in a numerical parametric study. Both the temperature and extrusion ratio showed a significant influence on the occurring maximum extrusion force as well as the material flow inside the LACE tool. The maximum force of 2.5 MN of the employed extrusion press was not exceeded. An uneven material flow was observed in the welding chamber, leading to an asymmetric position of the steel rod in the aluminum matrix.

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Section: Extrusion Experimentsmentioning

confidence: 71%

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

A Numerical Study on Co-Extrusion to Produce Coaxial Aluminum-Steel Compounds with Longitudinal Weld Seams

Behrens

Klose

Chugreev

et al. 2018

Metals

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“…However, both solutions require an actual joining operation beyond shaping and thus violate at least some process‐oriented hybrid material definitions. Co‐extrusion does not, however, and has been demonstrated, for example, for combinations of aluminum and titanium or aluminum and steel . Examples of structures in which separate processes are employed to create the hybrid are shown in Figure , ranging from local strengthening using weight‐optimized metallic inserts in FRP‐based sandwich structures to increase the transferable loads of bolted joints as in Figure a to the use of induction welding for joining FRP to metal structures (Figure b) and the realization of a hybrid titanium–aluminum seat rail via laser welding.…”

Section: Hybrid Materials and Structuresmentioning

confidence: 99%

New Materials and Processes for Transport Applications: Going Hybrid and Beyond

et al. 2019

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The present text introduces a Special Section of Advanced Engineering Materials linked to the symposium Advanced Materials for Transport Applications organized by the authors within the framework of the EUROMAT 2017 conference. It introduces the contributions that make up this Special Section, and takes the fact that a majority of them is related to the broader topic of hybrid materials and structures as a motivation for a short overview of this exciting area of research.

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“…First, a hybrid semifinished workpiece is manufactured by a joining process with two different metallic materials, in this case a high-strength case-hardened steel and an aluminum alloy. For this joining process, improved lateral angular co-extrusion (LACE) [11,12] is used, whereby failures caused by contaminated blocks or by significantly low material temperature in extrusion presses can be avoided. Subsequently, the workpiece is formed by die forging.…”

Section: A Hybrid Angular Contact Ball Bearing Bushingmentioning

confidence: 99%

Simulation of a Steel-Aluminum Composite Material Subjected to Rolling Contact Fatigue

et al. 2019

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Rolling bearings are frequently used machine elements in mechanical assemblies to connect rotating parts. Resource efficiency and reliability enhancement are considered to be important factors of rolling bearing development. One of the ways to meet these requirements is the tailored forming (TF) technology, which enables the functionalization of several metal layer composites in a single component. The so-called hybrid machine elements can be produced by co-extrusion of aluminum and steel and subsequent die forging, heat treatment, and machining. The TF rolling bearings made by this process can provide optimized characteristics that use aluminum to reduce weight and steel for a highly loaded contact zone between a rolling element and a bearing raceway. To evaluate the applicability and the potential of this technology, theoretical investigations are presented in this paper. The stress distribution under fully flooded conditions, caused by an external load in the contact between a rolling element and the TF outer ring of an angular contact ball bearing, is analyzed statically with the finite element method. The fatigue life of the TF component can be calculated for different external axial loads and manufacturing parameters, such as steel-to-aluminum volume ratios and osculation. As a damage model, the Ioannides and Harris fatigue model and the Dang Van multiaxial fatigue criterion were used. The results show that the fatigue life has high sensitivity to the steel-to-aluminum volume ratio. For the hybrid component with a steel layer thickness of 3 mm, 90 percent of the fatigue life of pure 100Cr6 steel bearing bushings is reached. In this FE model, residual stresses due to machining processes can be regarded as an initial state, which can increase the fatigue life of this TF machine component.

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Co-extrusion of semi-finished aluminium-steel compounds

Cited by 13 publications

References 8 publications

A Numerical Study on Co-Extrusion to Produce Coaxial Aluminum-Steel Compounds with Longitudinal Weld Seams

A Numerical Study on Co-Extrusion to Produce Coaxial Aluminum-Steel Compounds with Longitudinal Weld Seams

New Materials and Processes for Transport Applications: Going Hybrid and Beyond

Simulation of a Steel-Aluminum Composite Material Subjected to Rolling Contact Fatigue

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