Holistic development and characterization of an efficient manufacturing of detachable joints for aluminium and magnesium lightweight materials

金属轻质材料在交通工程的许多领域中被用于提高动态范围、优化资源和减少排放。铝构件通过焊接、粘接和螺纹连接制造。摩擦钻削作为一种成形工艺，在随后的螺纹制造过程中，利用局部材料膨胀，提供了在轻质型材中生产内螺纹的机会，其可用螺纹深度大于型材厚度。此外，直接制造提供了一个巨大的潜力，节省时间和成本相比，传统的螺纹machining.In本研究项目中，一个可靠的摩擦钻铝和镁合金AlSi 10 Mg和AZ 91的概念应开发产生可拆卸的连接通过螺纹形成。与攻丝相比，螺纹成形的优点在于它是一种非切削工艺，并导致边界区域的加工硬化。将使用先进的摩擦钻削工艺，工件前端扩展。操作范围明显扩大，无需额外的设计特征即可实现型材连接。应通过应用优化的测量传感器技术应用试验方法，以表征内螺纹的准静态和循环材料行为，并使用适量的试验样本。在生产过程中改变选定的工艺相关参数，并使用机械表征方法进行比较评价。结果反馈可实现资源优化和高效的螺纹加工。拟议研究项目的目的包括全面开发、表征和优化创新摩擦钻削工艺，以及随后的铝和镁合金螺纹制造。特别是基于模型的过程-结构-性能-关系的相关性有待研究。内螺纹的工艺相关的几何和微观结构特性与机械性能相关，由此基于结构的损伤机制分析导致对最佳工艺参数设计的理解。

Metallic lightweight materials are used for enhancing the dynamic range, resource optimization andemission reduction in many fields of traffic engineering. Aluminum components are manufactured by means of welded, adhesive and screw joints. Friction drilling, as a forming process with subsequent manufacturing of threads, offers the opportunity to produce an internal thread in lightweight profiles with a usable thread depth larger than the profile thickness, making use of local material expansion. Moreover, the direct manufacturing offers a huge potential for time and cost saving in comparison to conventional thread machining.In this research project a reliable friction drilling concept for aluminium and magnesium alloys AlSi10Mg and AZ91 shall be developed to generate detachable joints by means of thread forming. Thread forming offers the advantage that it is a non-cutting process and leads to work hardening in the border area compared with tapping. An advanced friction drilling process will be used, where the work piece is front-end expanded. The operational range is distinctly extended and joinings for profile connections can be realized without additional design features. Test methods shall be applied by means of application-optimized measurement sensor technology to characterize the quasistatic and cyclic material behavior of internal threads with an appropriate amount of tested specimens. Selected process-relevant parameters are varied during the manufacturing and comparatively evaluated with the mechanical characterization methods. The feedback of the results allows a resource optimized and efficient thread machining.The aim of the proposed research project includes the holistic development, characterization and optimization of an innovative friction drilling process with subsequent thread manufacturing in aluminium and magnesium alloys. Especially the model based correlations of the process-structure-property-relations are to be investigated. The process related geometrical and microstructural properties of internal threads are correlated with the mechanical properties, whereby a structure-based analysis of the damage mechanisms leads to a comprehension of an optimal process parameter designing.