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

Kruse, Jens; Mildebrath, Maximilian; Budde, Laura; Coors, Timm; Faqiri, Mohamad Yusuf; Barroi, Alexander; Stonis, Malte; Hassel, Thomas; Pape, Florian; Lammers, Marius; Hermsdorf, Jörg; Kaierle, Stefan; Overmeyer, Ludger; Poll, Gerhard

doi:10.3390/met10101336

Cited by 9 publications

(4 citation statements)

References 33 publications

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“…Various processes are known for the welding of protective claddings. These processes are laser metal deposition with powder (LMD-P), laser hot-wire cladding (LHWC), laser induction cladding (LIC), gas metal arc welding (GMAW) or plasma transferred arc welding (PTA) [2][3][4][5].…”

Section: Deposition Weldingmentioning

confidence: 99%

“…Another forming process used in Tailored Forming is CWR. Kruse et al investigated the cladding layer distribution after CWR of hybrid shafts with a base material of C22.8 and a cladding of X45CrSi9-3 and shafts with a base material of C22.8 and a cladding of 100Cr6 [5]. The shafts were successfully cross-wedge rolled without layer separation.…”

Section: Tailored Forming Process Chainmentioning

confidence: 99%

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

Budde

Biester

Merkel

et al. 2022

Prod. Eng. Res. Devel.

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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.

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Section: Deposition Weldingmentioning

confidence: 99%

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

Budde

Biester

Merkel

et al. 2022

Prod. Eng. Res. Devel.

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“…Kruse et al investigated the combination of a deposition welding process with X45CrSi9-3 (LHWC) and 100Cr6 (PTA) as cladding material on a shaft of mild steel C22.8 with a subsequent CWR process. Hybrid products with different cladding geometries could be formed successfully [26].…”

Section: Hot Forming Via Cross-wedge Rollingmentioning

confidence: 99%

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

Budde

Prasanthan

Kruse

et al. 2021

Int J Adv Manuf Technol

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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.

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“…Wu et al [ 18 ] presented the results of a study on the joining of two steel grades using a cross-wedge rolling process. Kruse et al [ 19 ] showed that the microstructure at the interface between two steels is significantly more favourable when the materials are joined by the cross-wedge rolling process than by conventional welding. Highly successful results in joining different grades of steel were obtained by Tomczak et al [ 20 ] using a three-roll skew rolling system.…”

Section: Introductionmentioning

confidence: 99%

Assessment of the Susceptibility to Material Fracture in the Cross-Wedge Rolling Process with Concave Tools

Bulzak

2022

Materials

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The internal cracking of forgings during the cross-wedge rolling (CWR) process is a serious limitation that prevents the correct implementation of this process. The phenomenon of material cracking in the CWR process reduces the technological and application possibilities of this highly efficient process, which can produce forgings with high geometric accuracy. This article presents the results of rolling forgings at different temperatures. An analysis of the results showed that the size of the resulting material fracture in the CWR process is related to the size of the ovalisation of the cross-section of the forging formed during rolling. On the basis of the observations made, it was proposed to realise the cross-wedge rolling process with concave tools. The use of tools with a concave geometry is intended to reduce the excessive flow of material in the rolling direction, which restrains the formation of the ovalisation of the cross-section of the forging. Numerical simulations were carried out comparing the rolling with flat tools and concave tools with different radii of the curvature. The results show that the use of concave tools reduces the ovality of the cross-section of the forging during rolling and reduces the value of the normalised Cockcroft–Latham (CL) fracture criterion.

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

Cited by 9 publications

References 33 publications

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

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

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

Assessment of the Susceptibility to Material Fracture in the Cross-Wedge Rolling Process with Concave Tools

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