scholarly journals Process chain for the manufacture of hybrid bearing bushings

2021 ◽  
Vol 15 (2) ◽  
pp. 137-150
Author(s):  
Susanne Elisabeth Thürer ◽  
Anna Chugreeva ◽  
Norman Heimes ◽  
Johanna Uhe ◽  
Bernd-Arno Behrens ◽  
...  
Keyword(s):  
Extrusion Process ◽  
Steel Tube ◽  
Case Hardening ◽  
Process Chain ◽  
Forming Process ◽  
Die Forging ◽  
Material Contact ◽  
Hybrid Bearing ◽  
Case Hardening Steel ◽  
Tailored Forming

AbstractThe current study presents a novel Tailored Forming process chain developed for the production of hybrid bearing bushings. In a first step, semi-finished products in the form of locally reinforced hollow profiles were produced using a new co-extrusion process. For this purpose, a modular tool concept was developed in which a steel tube made of a case-hardening steel, either C15 (AISI 1015) or 20MnCr5 (AISI 5120), is fed laterally into the tool. Inside the welding chamber, the steel tube is joined with the extruded aluminum alloy EN AW-6082. In the second step, sections from the compound profiles were formed into hybrid bearing bushings by die forging. In order to set the required forming temperatures for each material—aluminum and steel—simultaneously, a tailored heating strategy was developed, which enabled successful die forging of the hybrid workpiece to the desired bearing bushing geometry. Using either of the case-hardening steels in combination with aluminum, this novel process chain made it possible to produce intact hybrid bearing bushings, which showed both macroscopically and microscopically intimate material contact inside the compound zone.

scholarly journals Lateral Angular Co-Extrusion: Geometrical and Mechanical Properties of Compound Profiles

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1162
Author(s):  
Susanne Elisabeth Thürer ◽  
Julius Peddinghaus ◽  
Norman Heimes ◽  
Ferdi Caner Bayram ◽  
Burak Bal ◽  
...  
Keyword(s):  
Volume Fraction ◽  
Extrusion Process ◽  
Case Hardening ◽  
Compression Tests ◽  
Steel Tubes ◽  
Bonding Area ◽  
Bonding Mechanisms ◽  
Hybrid Bearing ◽  
Case Hardening Steel ◽  
Push Out

A novel co-extrusion process for the production of coaxially reinforced hollow profiles has been developed. Using this process, hybrid hollow profiles made of the aluminum alloy EN AW-6082 and the case-hardening steel 20MnCr5 (AISI 5120) were produced, which can be forged into hybrid bearing bushings by subsequent die forging. For the purpose of co-extrusion, a modular tooling concept was developed where steel tubes made of 20MnCr5 are fed laterally into the tool. This LACE (lateral angular co-extrusion) process allows for a variation of the volume fraction of the reinforcement by using steel tubes with different wall thicknesses, which enabled the production of compound profiles having reinforcement contents of either 14 vol.% or 34 vol.%. The shear strength of the bonding area of these samples was determined in push-out tests. Additionally, mechanical testing of segments of the hybrid profiles using shear compression tests was employed to provide information about the influence of different bonding mechanisms on the strength of the composite zone.

scholarly journals Contact Geometry Modification of Friction-Welded Semi-Finished Products to Improve the Bonding of Hybrid Components

Metals ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 115
Author(s):  
Bernd-Arno Behrens ◽  
Johanna Uhe ◽  
Tom Petersen ◽  
Florian Nürnberger ◽  
Christoph Kahra ◽  
...  
Keyword(s):  
Tensile Tests ◽  
Case Hardening ◽  
Process Chain ◽  
Forming Process ◽  
X Ray ◽  
Front End ◽  
Transition Area ◽  
Hardness Tests ◽  
Bonded Joint ◽  
Case Hardening Steel

To improve the bond strength of hybrid components when joined by friction welding, specimens with various front end surface geometries were evaluated. Rods made of aluminum AA6082 (AlSi1MgMn/EN AW-6082) and the case-hardening steel 20MnCr5 (AISI 5120) with adapted joining surface geometries were investigated to create both a form-locked and material-bonded joint. Eight different geometries were selected and tested. Subsequently, the joined components were metallographically examined to analyze the bonding and the resulting microstructures. The mechanical properties were tested by means of tensile tests and hardness measurements. Three geometrical variants with different locking types were identified as the most promising for further processing in a forming process chain due to the observed material bond and tensile strengths above 220 MPa. The hardness tests revealed an increase in the steel’s hardness and a softening of the aluminum near the transition area. Apparent intermetallic phases in the joining zone were analyzed by scanning electron microscopy (SEM) and an accumulation of silicon in the joining zone was detected by energy-dispersive X-ray spectroscopy (EDS).

scholarly journals Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing

2020 ◽  
Vol 14 (5-6) ◽  
pp. 569-581
Author(s):  
Bernd-Arno Behrens ◽  
Hans Jürgen Maier ◽  
Gerhard Poll ◽  
Peter Wriggers ◽  
Fadi Aldakheel ◽  
...  
Keyword(s):  
Numerical Simulations ◽  
Inductive Heating ◽  
Process Chain ◽  
Functional Surface ◽  
Machining Processes ◽  
Forming Process ◽  
Numerical Investigations ◽  
Forging Process ◽  
Die Forging ◽  
Hybrid Bearing

AbstractThis contribution deals with the numerical investigations to develop a novel process chain for hybrid solid components using Tailored Forming. For manufacturing a hybrid bearing bushing, co-extrusion is the first step to produce hybrid semi-finished workpieces followed by a die forging process, machining processes and hardening. Combining aluminium with steel, compounds with wear-resistant functional surfaces and reduced weight are realised. Numerical simulations are a decisive part of the process chain design, for example to determine suitable process parameters for the co-extrusion process and to predict the thickness of intermetallic phases in the joining zone using a macroscopic phenomenological model. A numerical design including a tool analysis of the die forging process was carried out taking the experimentally determined material properties and the temperature profile after inductive heating into account. Additionally, the damage and fatigue behaviour of the polycrystalline material of the joining zone are modelled at the microstructure level. Moreover, a new discretization scheme, namely the virtual element method, which is more efficient at grain level, is developed regarding a crystal plasticity framework. Numerical simulations are used to develop inductive heating strategies for the forming process and for the design of the inductive hardening of the functional surface at the end of the process chain. In order to investigate the performance of this hybrid machine element under application-oriented conditions, a contact simulation is linked with a statistical damage model to calculate the bearing fatigue. In this study, a general overview of the individual process steps is given and results of the respective models are presented.

scholarly journals Mechanical Properties of Co-Extruded Aluminium-Steel Compounds

2017 ◽  
Vol 742 ◽  
pp. 512-519 ◽  
Author(s):  
Susanne Elisabeth Thürer ◽  
Johanna Uhe ◽  
Oleksandr Golovko ◽  
Christian Bonk ◽  
Anas Bouguecha ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Tests ◽  
Steel Tube ◽  
Research Centre ◽  
Tool Geometry ◽  
Case Hardening ◽  
Process Step ◽  
Process Chains ◽  
Ultrasonic Assisted ◽  
Case Hardening Steel

Within the scope of the Collaborative Research Centre (CRC) 1153 novel process chains for the production of hybrid solid components by Tailored Forming are developed at the Leibniz Universität Hannover. The combination of e. g. aluminium with steel allows to produce hybrid compounds with wear-resistant functional surfaces and reduced weight. In these process chains, joining takes place as the first step to produce hybrid semi-finished products by friction welding, cladding, ultrasonic assisted laser welding or co-extrusion, which are subsequently subjected to various forming processes such as forging or impact extrusion. The coaxially joined hybrid semi-finished components investigated in this work were produced by means of the lateral angular co-extrusion (LACE) process using the aluminium alloy EN AW-6082 and the case-hardening steel 20MnCr5. These semi-finished products shall be suited to produce hybrid bearing bushings by die forging in a subsequent process step. Initial investigations for the determination of the process parameters and the appropriate tool geometry were made using a steel rod. In future investigations, a steel tube will replace the steel rod in order to produce hybrid semi-finished products, which can be fully integrated into the process chain. The mechanical properties of the profile were determined at different positions along its length. For this purpose, the quality of the joining zone between aluminium and steel as a function of the profile position was examined by means of push-out tests. Moreover, the mechanical properties of the aluminium component’s longitudinal weld seam were determined by micro-tensile-tests.

AISI 4320

Alloy Digest ◽  
1959 ◽  
Vol 8 (2) ◽  
Keyword(s):  
Fracture Toughness ◽  
Corrosion Resistance ◽  
Physical Properties ◽  
Heat Treating ◽  
Case Hardening ◽  
High Toughness ◽  
Nickel Chromium ◽  
Steel Mills ◽  
Shock Resistance ◽  
Case Hardening Steel

Abstract AISI 4320 is a nickel-chromium-molybdenum case hardening steel having high toughness and shock resistance. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties as well as fracture toughness. It also includes information on corrosion resistance as well as forming, heat treating, machining, and joining. Filing Code: SA-80. Producer or source: Alloy steel mills and foundries.

AISI 8615

Alloy Digest ◽  
1965 ◽  
Vol 14 (7) ◽  
Keyword(s):  
Fracture Toughness ◽  
Alloy Steel ◽  
Heat Treating ◽  
Case Hardening ◽  
Low Carbon ◽  
Heavy Duty ◽  
Core Strength ◽  
Nickel Chromium ◽  
Steel Mills ◽  
Case Hardening Steel

Abstract AISI 8615 is a low-carbon, nickel-chromium-molybdenum alloy steel capable of producing high core strength and toughness. It is a case hardening steel recommended for heavy duty gears, cams, shafts, chains, fasteners, piston pins, etc. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties as well as fracture toughness. It also includes information on forming, heat treating, machining, and joining. Filing Code: SA-180. Producer or source: Alloy steel mills and foundries.

AISI 3120

Alloy Digest ◽  
1960 ◽  
Vol 9 (4) ◽  
Keyword(s):  
Physical Properties ◽  
Tensile Properties ◽  
Alloy Steel ◽  
Heat Treating ◽  
Case Hardening ◽  
Low Carbon ◽  
Steel Mills ◽  
Shock Resistance ◽  
Case Hardening Steel

Abstract AISI 3120 is a low-carbon, chromium-nickel case-hardening steel offering good toughness and shock resistance. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties. It also includes information on forming, heat treating, machining, and joining. Filing Code: SA-97. Producer or source: Alloy steel mills and foundries.

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