Process chain for the manufacture of hybrid bearing bushings

Thürer, Susanne Elisabeth; Chugreeva, Anna; Heimes, Norman; Uhe, Johanna; Behrens, Bernd‐Arno; Maier, Hans Jürgen; Klose, Christian

doi:10.1007/s11740-021-01028-4

Cited by 4 publications

(6 citation statements)

References 23 publications

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“…However, Weidenmann et al achieved this value only by additional heat treatment after the co-extrusion. Although the LACE profiles should also have the potential for a further increase in strength by heat treatment, this has not yet been considered in this work, since premature strengthening of the hybrid semi-finished products would only be of limited use for the subsequent closed-die forging process [ 2 ].…”

Section: Discussionmentioning

confidence: 99%

“…The LACE process has already been described in detail in Refs. [ 2 , 18 ], and thus only the key elements are explained here. Since the LACE process involves feeding a rigid reinforcing element instead of a wire, a die was designed with a mandrel part supported by three support arms in the die housing.…”

Section: Methodsmentioning

confidence: 99%

“…In the second step, these semis are forged into bearing bushings, and thus the joint zone established through co-extrusion undergoes a thermo-mechanical treatment. The process chain developed has been described in more detail in a previous publication [ 2 ].…”

Section: Introductionmentioning

confidence: 99%

“…As with tailored blanks, various welding processes can be used to join hybrid massive components. In contrast, profile-shaped hybrid components are manufactured by co-extrusion, which has been established for the production of hybrid semi-finished products consisting of EN AW-6082 and C15, as well as 20MnCr5 steel [ 2 ]. These hybrid profiles have been processed further into hybrid bearing bushings.…”

Section: Introductionmentioning

confidence: 99%

“…The Lateral Angular Co-Extrusion (LACE) process for the production of hybrid hollow sections from the aluminum alloy EN AW-6082 combined with either C15 or 20MnCr5 steel has previously been described in detail [ 2 , 18 ]. It has been unclear, however, how various steel alloys will affect the properties of the bonding zone since the diffusion paths of individual alloying elements from the joining partners will be different between each other.…”

Section: Introductionmentioning

confidence: 99%

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Characterization of the Interface between Aluminum and Iron in Co-Extruded Semi-Finished Products

Thürer¹,

Peters²,

Heidenblut³

et al. 2022

Materials

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Within the framework of the Collaborative Research Center 1153, we investigated novel process chains for the production of bulk components with different metals as joining partners. In the present study, the co-extrusion of coaxially reinforced hollow profiles was employed to manufacture semi-finished products for a subsequent die-forging process, which was then used for the manufacture of hybrid bearing bushings. The hybrid hollow profiles, made of the aluminum alloy EN AW-6082 paired with either the case-hardening steel 20MnCr5, the stainless steel X5CrNi18-10, or the rolling bearing steel 100Cr6, were produced by Lateral Angular Co-Extrusion. Push-out tests on hybrid hollow sections over the entire sample cross-section showed shear strengths of 44 MPa ± 8 MPa (100Cr6) up to 63 MPa ± 5 MPa (X5CrNi18-10). In particular, the influence of force and form closure on the joint zone could be determined using specimen segments tested in shear compression. Locally, shear strengths of up to 131 MPa (X5CrNi18-10) were demonstrated in the shear compression test. From these samples, lamellae for microstructural analysis were prepared with a Focused Ion Beam. Detailed analyses showed that for all material combinations, a material bond in the form of an ultra-thin intermetallic phase seam with a thickness of up to 50 nm could be established.

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Section: Discussionmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Characterization of the Interface between Aluminum and Iron in Co-Extruded Semi-Finished Products

Thürer¹,

Peters²,

Heidenblut³

et al. 2022

Materials

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Non-destructive Evaluation of Workpiece Properties along the Hybrid Bearing Bushing Process Chain

Fricke

Thürer

Kahra

et al. 2022

J. of Materi Eng and Perform

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To combine the advantages of two materials, hybrid bulk metal workpieces are attractive for subsequent processes such as metal forming. However, hybrid materials rely on the initial bond strength for the effective transfer of applied loads. Thus, a non-destructive evaluation of the bonding along the production process chain is of high interest. To evaluate to what extent non-destructive testing can be employed to monitor the bonding quality between the joining partners steel and aluminum and to characterize the age hardening condition of the aluminum component, ultrasonic testing and electrical conductivity measurements were applied. It was found that a lateral angular co-extrusion process can create homogeneous bonding although the electrical conductivity of the aluminum is altered during processing. A previous bonding before the subsequent die forging process leads to a sufficient bonding in areas with little deformation and is therefore, advantageous compared to unjoined semi-finished products, which do not form a bonding if the deformation ratio is too small. An influence of the subsequent heat treatment on the bonding is not visible in the ultrasonic testing signals though a homogenized electrical conductivity can be detected, which indicates uniform artificial aging conditions of the aluminum alloy

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Tailored Forming of hybrid bulk metal components

et al. 2022

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Multi-material bulk metal components allow for a resource efficient and functionally structured component design, with a load adaptation achieved in certain functional areas by using similar and dissimilar material combinations. One possibility for the production of hybrid bulk metal components is Tailored Forming, in which pre-joined semi-finished products are hot-formed using novel process chains. By means of Tailored Forming, the properties of the joining zone are geometrically and thermomechanically influenced during the forming process. Based on this motivation, forming processes (die forging, impact extrusion) coupled with adapted inductive heating strategies were designed using numerical simulations and successfully realised in the following work in order to produce demonstrator components with serial or coaxial material arrangements. The quality of the joining zone was investigated through metallographic and SEM imaging, tensile tests and life cycle tests. By selecting suitable materials, it was possible to achieve weight savings of 22% for a pinion shaft and up to 40% for a bearing bush in the material combination of steel and aluminium with sufficient strength for the respective application. It was shown that the intermetallic phases formed after friction welding barely grow during the forming process. By adjusting the heat treatment of the aluminium, the growth of the IMP can also be reduced in this process step. Furthermore, for steel-steel components alloy savings of up to 51% with regard to chromium could be achieved when using low-alloy steel as a substitute for high-alloy steel parts in less loaded sections. The welded microstructure of a cladded bearing washer could be transformed into a homogeneous fine-grained microstructure by forming. The lifetime of tailored formed washers nearly reached those of high-alloyed mono-material components.

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Process chain for the manufacture of hybrid bearing bushings

Cited by 4 publications

References 23 publications

Characterization of the Interface between Aluminum and Iron in Co-Extruded Semi-Finished Products

Characterization of the Interface between Aluminum and Iron in Co-Extruded Semi-Finished Products

Non-destructive Evaluation of Workpiece Properties along the Hybrid Bearing Bushing Process Chain

Tailored Forming of hybrid bulk metal components

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