Tailored Forming of hybrid bulk metal components

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