Process combination of combined deep drawing and cold forging

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In the first funding period, it was shown that the process of combined deep-drawing and cold forging can be used to produce hybrid shafts, consisting of a lightweight core and a high strength steel shell.The goals of the second funding period is the adaptation of the process in order to increase the possible component spectrum, as well as to increase the bond quality between the composite partners. The usage of perforated circular sheets is supposed to link the processes of hole expansion and forward extrusion, in order to enable coating of arbitrary shaft regions. In addition to this, multi-stage deep-drawing is used to produce shafts that are covered with a high strength steel over its complete length. In order to increase the resulting bond strengths in the basic process as well as its variations, the application of a counter-pressure is investigated in order to further enlarge the process window.A variation of the material combinations is investigated in order to further increase the lightweight potential (e. g. magnesium as a core material). Due to the hexagonal lattice structure, magnesium and its alloys are difficult to form. In this regard it will be investigated to what extent the hydrostatic pressure resulting from the surrounding high strength shell will help in the joint forming process. Lastly, new features are investigated by combination of new material combinations, e. g. the use of copper as a steel shell for increasing the electrical conductivity.