Treatments of steel sheets for the high pressure die casting of aluminum/steel sheet-metal hybrids with low gap and distortion formation (BeST)

在第一个项目中，可以证明，根据工艺和材料条件，可以通过在高压压铸中以材料、力或成形配合的方式对镶件进行涂层和结构，在当地生产几何形状简单的铝铸/钢混合接头。第二阶段的重点是机翼工具，作为一种几何上更复杂的混合工具。这使得能够科学地调查各个工艺步骤的相关参数和机制，以及它们在所需复杂程度上的相互作用。因此，规划项目的总体目标一方面是经验。开发相关机制及其对生产链上工艺和材料参数的依赖关系。另一方面，将开发一个模块化的总体模型，其中包括对各个工艺步骤的建模，以及根据实验和材料和工艺数据数据库建立的标准函数。标准函数在统计安全的基础上定义了例如各个工艺参数和结构类型与所实现的复合性能的相关性。总之，实验工作和模块化整体模型的开发应该有助于理解板材/铸造混杂复合材料在压铸中的基本机理，即使在复杂的要求下也是如此，从而能够生产出工艺可靠的产品。机翼工具的凹凸设计和基板上的穿孔迫使熔体偏转，一方面导致铸件收缩到板材上和板材上，另一方面导致复杂的、与位置有关的流动条件。所使用的结构和涂层还会影响局部形貌和元素浓度，从而影响润湿、流动和凝固。系统的现场测量用于检查和评估模拟，以便能够对局部表面预处理进行工艺相关的设计。在此基础上，将复合质量与局部工艺变量相关联，建立了预测复合质量的具体准则函数。借助这些判据函数并结合热物理模拟，可以确定适合组织的衬底区域和/或涂层更有可能实现铝铸件与钢之间最佳结合的区域。这些研究补充了第一个关于二维复合材料生产的项目所获得的知识，并允许将以前的实验和模拟工作转移到任何复杂的部件。

In the first project it could be shown that geometrically simple, hybrid Al-cast/steel joints can be produced locally by coating and structuring of the insert in a material-, force- or form-fit manner in high-pressure die casting, depending on the process and material conditions. The second phase focuses on the WING tool as a geometrically more complex hybrid tool. This allows the scientific investigation of relevant parameters and mechanisms of the individual process steps and their interactions at the required level of complexity. Therefore, the overall goal of the planned project is on the one hand the exp. development of the relevant mechanisms and their dependencies on process and material parameters along the production chain. On the other hand, a modular overall model is to be developed in which the modelling of individual process steps is included as well as criterion functions created on the basis of the experiments and the database of material and process data. The criterion functions define the correlation of e.g. individual process parameters and the type of structuring with the achieved composite properties on a statistically secured basis. In sum, the experimental work and the development of a modular overall model should lead to an understanding of the basic mechanisms of hybrid sheet metal/cast composites in die casting, even for complex requirements, and thus enable their process-reliable production. The convex and concave design of the WING tool and the perforations in the substrate force the melt to be deflected, which on the one hand causes the casting to shrink onto and off the sheet metal and on the other results in complex, location-dependent flow conditions. The structures and coatings used can also influence the local topography and element concentration and thus affect wetting, flow and solidification. Systematic in situ measurements are used to check and evaluate simulations in order to enable process-dependent design of the local surface pretreatment. Furthermore, the composite quality is to be correlated with the local process variables and specific criterion functions for predicting the composite quality are to be established. With the help of these criterion functions in combination with thermophysical simulations, e.g. areas of the substrate that are suitable for structuring and/or those areas in which a coating is more likely to enable the optimum bond between aluminium casting and steel are to be determined. These investigations complement the knowledge gained in the first project on composite production on a two-dimensional level and allow the transferability of the previous experimental and simulative work to components of any complexity.