Manufacturing of Steel-Reinforced Aluminum Products by Combining Hot Extrusion and Closed-Die Forging

Foydl, Annika; Pfeiffer, I.; Kammler, Matthias; Pietzka, Daniel; Matthias, Thorsten; Jäger, Andreas; Tekkaya, A. Erman; Behrens, Bernd‐Arno

doi:10.4028/www.scientific.net/kem.504-506.481

Cited by 16 publications

(7 citation statements)

References 5 publications

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“…Foydl et al investigated steel-reinforced aluminum. They used continuous reinforcement only for co-extrusion and discontinuous for forging, and produced a component with different distributions of the wire reinforcement [22]. This was confirmed by Feuerhack [23], who investigated the processing of co-extruded Al-Mg rods by die forging.…”

Section: Introductionsupporting

confidence: 52%

Process Chain for the Production of a Bimetal Component from Mg with a Complete Al Cladding

Förster

Binotsch

Awiszus

2018

Metals

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With respect to its density, magnesium (Mg) has a high potential for lightweight components. Nevertheless, the industrial application of Mg is limited due to, for example, its sensitivity to corrosion. To increase the applicability of Mg, a process chain for the production of a Mg component with a complete aluminum (Al) cladding is presented. Hydrostatic co-extrusion was used to produce bar-shaped rods with a diameter of 20 mm. The bonding between the materials was verified by ultrasonic testing. Specimens with a length of 79 mm were cut off from the rods and forged by using a two-staged process. After the first step (Heading), the Mg core was removed partially by drilling to ensure a complete enclosing of the remaining Mg during the second forging step (Net shape forging). The geometry of the drilling hole and the heading die design were dimensioned with the Finite Element-simulation software FORGE. Hence, a complete Al-enclosed Mg component was achieved by using the described process chain and forming processes. Microstructural investigations confirm the formation of an intermetallic interface as expected.

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Section: Introductionsupporting

confidence: 52%

Process Chain for the Production of a Bimetal Component from Mg with a Complete Al Cladding

Förster

Binotsch

Awiszus

2018

Metals

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“…Furthermore, in the studies by Foydl et al, an extrusion process was developed, in which aluminium profiles were reinforced by steel wires. For further processing into connecting rods, the components were cut to size and used as semi-finished products for a die forging process [8]. Basic research into joining by friction welding and subsequent upsetting of solid hybrid components made of copper and aluminium or steel and copper was carried out by Domblesky et al The results obtained from upsetting indicate a good workability of hybrid materials [9].…”

Section: State Of the Artmentioning

confidence: 99%

Investigation of the joining zone formation of impact extruded hybrid components by varied forming sequence and partial cooling

PIWEK

2023

Materials Research Proceedings

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Abstract. Hybrid material concepts enable the combination of beneficial properties of different materials to extend the limited potential of monolithic components. When it comes to steel and aluminium, a wear-resistant and a lightweight metal are combined to produce a weight-reduced high-performance component with load-adapted areas. A method to create hybrid gear shafts is a novel approach called Tailored Forming. The process chain consists of joining e. g. by friction welding and subsequent impact extrusion under elevated temperature. Before forming, an axial temperature gradient is set in the serial arranged semi-finished products to adjust the different yield stresses of the dissimilar materials through induction heating of the steel part. The subsequent forming is intended to positively influence the joining zone thermo-mechanically and geometrically. However, prior work indicated a limitation of the influence on the joining zone in forward rod extrusion. Therefore, approaches are being researched that enable a stronger formation of the joining zone geometry to influence the resulting bond qualities through surface enlargement. A forward rod extrusion process of friction welded hybrid semi-finished products made of 20MnCr5 (AISI 5120H) combined with EN AW-6082 (AA6082) was carried out experimentally. Complementary to prior investigations, in which mainly the aluminium section was reduced through the die angle followed by the steel, the forming sequence of the materials was reversed to increase the joining zone surface with variation of the forming path. Additionally, a cooling of the aluminium side was realized through an immersion cooling to adjust maximum temperature gradients and further equalize the different yield stresses. Hardness tests, metallographic and SEM images of cross-sections were taken to evaluate the bond quality with regard to the temperature influence, joining zone formation, occurring defects and the resulting intermetallic compound (IMC). Impact extrusion with initially steel formed followed by aluminium resulted in a spherical formation of the joining zone and consequently in greater surface area, but also lead to partial defects in the IMC. The partial cooling of the aluminium allowed higher temperature gradients to be set, thus reducing defects through improved material flow in the joining zone.

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“…Tekkaya et al investigated the process route of joined and formed steel-reinforced aluminium profiles resulting in good bond strengths [8]. Similar to this, Foydl et al developed a hot compound-extrusion process, in which steel reinforcements are inserted into aluminium billets to create strengthened components [9]. However, the reinforcing steel elements used are comparatively small and do not serve as a fully separate functional areas.…”

Section: State Of the Artmentioning

confidence: 99%

Comparison of the Joining Zone development of Hybrid Semi-Finished Products after different Extrusion Processes

PIWEK

UHE

Peddinghaus

et al. 2022

METAL 2022 Conference Proeedings

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The use of hybrid semi-finished products made of aluminium and steel enables the production of components with locally adapted properties, i.e. high strength and wear-resistance with reduced weight. In the scope of this work, different impact extrusion processes for the forming of friction-welded hybrid semi-finished products consisting of steel (20MnCr5) and aluminium (EN AW-6082) were developed and experimentally implemented. The resulting material flows were intended to enable different joining zone geometries as well as to evaluate the influence of a thermo-mechanical treatment during the impact extrusion process on the quality of the joining zone. For this purpose, a full-forward extrusion, cup-backward extrusion, combined cup-backward-full-forward extrusion and a hollow-forward extrusion process were investigated. The evaluation of the resulting component quality was carried out based on metallographic images, which provide microstructural information about the forming-related influence on the friction welded joining zone. Based on the characteristic values determined, a correlation between the reproducibility and quality of the joining zone properties and the type of impact extrusion process is deduced. The backward extrusion processes have proven to be the best processes in terms of influencing the joining zone geometry. Further, the effect of forward extrusion showed no significant influence on the joining zone geometry, even resulting in a reduction of the joining zone formation in the combined cup-backward-full-forward extrusion process.

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Manufacturing of Steel-Reinforced Aluminum Products by Combining Hot Extrusion and Closed-Die Forging

Cited by 16 publications

References 5 publications

Process Chain for the Production of a Bimetal Component from Mg with a Complete Al Cladding

Process Chain for the Production of a Bimetal Component from Mg with a Complete Al Cladding

Investigation of the joining zone formation of impact extruded hybrid components by varied forming sequence and partial cooling

Comparison of the Joining Zone development of Hybrid Semi-Finished Products after different Extrusion Processes

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