Investigation of the joining zone of laser welded and cross wedge rolled hybrid parts

Int J Adv Manuf Technol

Prasanthan

Kruse

et al. 2021

Self Cite

Due to the increased integration of functions, many components have to meet high and sometimes contradictory requirements. One way to solve this problem is Tailored Forming. Here, hybrid semi-finished products are manufactured by a joining or cladding process, which are then hot-formed and finished. For the design of hybrid components for a possible later industrial application, knowledge about properties of hybrid components is required. In this paper it is investigated how the respective process steps of the Tailored Forming process chain change the surface and subsurface properties of the applied cladding layer. For this purpose, shafts made of unalloyed steel are provided with a high-alloy austenitic steel X2CrNiMo19-12 cladding by laser hot-wire cladding. Subsequently, hot forming is carried out by cross-wedge rolling and the finishing by turning and deep rolling. After each process step, the subsurface properties of the cladding such as microstructure, hardness and residual stress state are examined. Thus, the influence of different process steps on the subsurface properties in the process chain of manufacturing hybrid shafts can be analyzed. This knowledge is necessary for the specific adjustment of defined properties for a required application behavior.

“…14). The transformation of the welding microstructure in a classic forming microstructure after hot forming has been shown in previous work [1].…”

Section: Microstructure and Hardnessmentioning

confidence: 54%

Section: Introductionmentioning

confidence: 99%

Investigation of the influence of the forming process and finishing processes on the properties of the surface and subsurface of hybrid components

Int J Adv Manuf Technol

Prasanthan

Kruse

et al. 2021

Self Cite

“…However, it is also possible to reduce the cost and/or weight of the shaft by joining shafts made of two different materials in series. Blohm et al investigated hybrid shafts of the material combination C22 and 20MnCr5 [21]. Two base cylinders with a diameter of 30 mm and a length of 50 mm were joined by laser deep welding and formed by CWR.…”

Section: Tailored Forming Process Chainmentioning

confidence: 99%

Investigation of the material combination 20MnCr5 and X45CrSi9-3 in the Tailored Forming of shafts with bearing seats

Biester

Merkel

et al. 2022

Prod. Eng. Res. Devel.

Self Cite

The Tailored Forming process chain is used to manufacture hybrid components and consists of a joining process or Additive Manufacturing for various materials (e.g. deposition welding), subsequent hot forming, machining and heat treatment. In this way, components can be produced with materials adapted to the load case. For this paper, hybrid shafts are produced by deposition welding of a cladding made of X45CrSi9-3 onto a workpiece made from 20MnCr5. The hybrid shafts are then formed by means of cross-wedge rolling. It is investigated, how the thickness of the cladding and the type of cooling after hot forming (in air or in water) affect the properties of the cladding. The hybrid shafts are formed without layer separation. However, slight core loosening occurres in the area of the bearing seat due to the Mannesmann effect. The microhardness of the cladding is only slightly effected by the cooling strategy, while the microhardness of the base material is significantly higher in water cooled shafts. The microstructure of the cladding after both cooling strategies consists mainly of martensite. In the base material, air cooling results in a mainly ferritic microstructure with grains of ferrite-pearlite. Quenching in water results in a microstructure containing mainly martensite.

“…Due to the production process of the components used in this work, a simulation of the welding influence is not necessary. As Blohm et al [24] showed, a hot forming process after a welding process could completely eliminate the heat effects of welding on the steel structure. The reason for this is the complete re-austenitization of the microstructure with subsequent microstructure formation, which neutralizes previous residual stresses.…”

Section: Welding and Formingmentioning

confidence: 99%

Numerical Simulation and Experimental Validation of the Cladding Material Distribution of Hybrid Semi-Finished Products Produced by Deposition Welding and Cross-Wedge Rolling

Kruse

Mildebrath

et al. 2020

Metals

Self Cite

The service life of rolling contacts is dependent on many factors. The choice of materials in particular has a major influence on when, for example, a ball bearing may fail. Within an exemplary process chain for the production of hybrid high-performance components through tailored forming, hybrid solid components made of at least two different steel alloys are investigated. The aim is to create parts that have improved properties compared to monolithic parts of the same geometry. In order to achieve this, several materials are joined prior to a forming operation. In this work, hybrid shafts created by either plasma (PTA) or laser metal deposition (LMD-W) welding are formed via cross-wedge rolling (CWR) to investigate the resulting thickness of the material deposited in the area of the bearing seat. Additionally, finite element analysis (FEA) simulations of the CWR process are compared with experimental CWR results to validate the coating thickness estimation done via simulation. This allows for more accurate predictions of the cladding material geometry after CWR, and the desired welding seam geometry can be selected by calculating the cladding thickness via CWR simulation.