SFB 1153: Process Chain for Manufacturing of Hybrid High Performance Components by Tailored Forming

合作研究中心（CRC） 1153旨在确定基于新工艺链的混合大块金属部件的潜力，并开发必要的制造工艺。混合大块金属部件的传统制造和生产工艺只在成形过程中或制造链的末端进行连接过程，与此相反，CRC使用在成形过程之前连接的半成品。这使得生产满足不同结构和功能区域的本地要求的组件比单材料组件要好得多。通过在一个部件中组合不同的材料，可以减少部件的重量或成本，同时通过局部使用轻质材料或将其与高质量合金结合来保持或提高性能。与现有的制造工艺相比，在定制成型工艺链中，半成品的简单几何形状便于处理和可靠地生产粘合区。通过对后续成形过程中材料流动的具体控制，还可以影响连接区的几何形状，这在目前的传统连接工艺中是不可行的。成形过程中的热力学影响也提高了连接区的质量。CRC 1153的创新方法包括通过建立必要的工艺指南和推导特定规律，从半成品工件到可用部件的制造和开发过程的整体视图。到目前为止，定制成型工艺的技术就绪水平将在第三个资助期内进一步提高。为此，要增加个体和整体流程链的健壮性，并扩展表征选项和建模方法等。分散开发的工艺的物理和数字整合将能够在系列锻造试验中验证工艺链的稳健性。与此同时，附加测量技术的集成以及相关工艺数据的一致获取和提供允许推导超出单个工艺步骤的控制算法，从而可重复地增加生产混合高性能组件的工艺参数空间。为了能够将已开发的创新技术转化为工业实践，需要评估可能性，以评估已开发技术的经济和生态附加值。为此目的，在以前的经济评价方法中将考虑到生态影响变量，这些变量与技术改进一起证明了新技术的总体潜力。

The Collaborative Research Center (CRC) 1153 aims at identifying the potential of hybrid bulk-metal components based on a novel process chain and at developing the necessary manufacturing processes. In contrast to the conventional manufacturing and production processes for hybrid bulk-metal components where the joining process only takes place during forming or at the end of the manufacturing chain, the CRC uses semi-finished products that are joined before the forming process. This allows for the production of components that meet the local requirements of different structural and functional areas within themselves much better than mono-material components. By combining different materials within a component, the weight or the costs of the component can be reduced while maintaining or improving performance either by the local use of lightweight materials or by combining it with high-quality alloys. In comparison with existing manufacturing processes, the simple geometry of the semi-finished products in the tailored forming process chain facilitates handling and a reliable production of a cohesive joining zone. By means of specifically controlling the material flow during the subsequent forming, the resulting joining zone geometry can be influenced as well, which is currently not feasible in conventional joining processes. The thermomechanical influence during forming also improves the quality of the joining zones. The innovative approach of the CRC 1153 includes an integral view of the manufacturing and development process from the semi-finished workpiece to the usable component by establishing the necessary process guidelines and deriving specific laws. The technology-readiness level of tailored forming processes developed to date is to be further increased in the third funding period. To this end, the robustness of the individual and overall process chain is to be increased and the characterisation options and modelling approaches expanded, among other things. The physical and digital consolidation of the decentrally developed processes will enable the verification of the robustness of the process chain in serial forging tests. At the same time, the integration of additional measurement technology as well as the consistent acquisition and provision of relevant process data permits the derivation of control algorithms beyond the individual process steps, thus reproducibly increasing the process parameter space for the production of hybrid high-performance components. In order to be able to transfer the developed innovations into industrial practice, evaluation possibilities are required to assess the economic and ecological added value of the developed technology. For this purpose, ecological influencing variables will be taken into account in previous economic evaluation approaches, which, together with the technological enhancements, prove the overall potential of the new technology.