Compound forging of hybrid powder-solid-parts made of steel and aluminum

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In the proposed project, the suitability of the process combination of powder-metallurgy and compound forging for the production of hybrid steel-aluminum components will be examined fundamentally and the process limits will be identified.Due to the required inhomogeneous heating of the hybrid raw part, a local melting of the aluminum core may occur during the compound forming process when aluminum contacts steel. This ensures the formation of intermetallic phases in the joining zone of the hybrid components, where the thickness of the intermetallic phase seam is a criterion for the global bonding strength.The aim of this research project is to influence the intermetallic phase formation during the compound forging process by adding alloying elements in the joining zone. For this purpose, the aluminum core of the hybrid raw part is manufactured with a graded structure in the surface, respectively in the joining zone, by powder metallurgy. Subsequently upon the compound forging process, hybrid powder-solid-parts will be form-joined, firmly-bonded-joined and nonpositive-joined and the influence of various alloying elements and boundary layer thicknesses on the intermetallic phase seam thickness will be quantified.The use of the process combination of powder-metallurgy and compound forging for the production of hybrid components made of steel and aluminum is a promising method to manufacture functional parts by applying resource-saving process steps.