Hybrid interaction during and after thixoforging of multi material systems

在能源和资源成本上升的时代，提高生产和应用的效率是开发和优化制造工艺的重要技术驱动因素。因此，在局部优化和负载情况适应的混合构件的生产过程中，通过减轻重量，可以为节能和节约资源提供有效的投入。本研究项目的目的是开发具有金属-金属键的混合构件的触变锻造工艺。因此，不同金属材料之间在触变锻造过程中和之后发生的金属间化合物相的表征是一个主要的研究课题。在第一个供资期间，重点是制定两条工艺路线以及要生产的金属化合物的具体设计，同时考虑到不同材料连接区和过渡区的相互作用机制。虽然在第一个资助期，简单的圆盘部件最初是在实际成形试验过程中生产的，但在第二个资金期，将实施具有更复杂流动路径的非旋转对称部件几何形状，以便更深入地了解两种不同的半液态金属合金同时成形时的流动行为。此外，在第一个资助期内，混合半成品的触变锻造模拟说明中出现的缺陷将被第二个资助期内的拟议研究工作所弥补。在第二个资助期内，将追求下列科学目标：-研究考虑复杂流动路径的触变锻造分级半成品的联合成形和通过有限元模拟对材料流动进行建模-开发用于有限元模拟的数值模型，以便通过不同半固态金属合金的流动曲线来描述触变材料的性质--不同材料之间在加热和加热后的材料转变的研究成型工艺--混合部件的功能性能的测定，特别是板条箱接合区的机械性能--将所获得的知识转移到由熔点有显著差异的材料制成的混合半成品(温差和GT；100K)

In times of rising energy and resource costs, improvement of efficiency in production and application is an important technological driver for development and optimization of manufacturing processes. Thereby, an effective input for saving energy and the conservation of resources is contributed by weight reductions within the production of locally optimized and on load cases adapted hybrid components.The aim of this research project is to develop the process for thixoforging of hybrid components with metal-to-metal bonds. Thereby, the characterization of the intermetallic phases occurring both during and after the thixoforging process between the different metallic materials is a major research topic. In the first funding period, the focus was on the development of two process routes as well as the specific design of the metallic compounds to be produced, taking into account the interaction mechanisms occurring in the joining and transition zones of the different materials. While in the first funding period, simple disk components were initially produced in the course of the real forming tests, a non-rotationally symmetrical component geometry with more complex flow paths is to be implemented in the second funding period in order to gain a deeper understanding of the flow behaviour during simultaneous forming of two different semi-liquid metal alloys. Furthermore, the deficits that occured in the simulative illustration of thixoforging of hybrid semi-finished products during the first funding period are to be remedied by the proposed research work in the second funding period.The following scientific objectives will be pursued within the second funding period:- Investigations of the joint forming of graded semi-finished products by thixoforging taking into account complex flow paths and modelling of the material flow by means of FEM simulation- Development of a numerical model for FEM simulation in order to describe thixotropic material properties by flow curves of different semi-solid metal alloys- Investigations of the material transitions between the different materials during heating and after the forming process- Determination of the functional properties of the hybrid components and in particular the mechanical properties of the crated joining zones- Transfer of the knowledge gained to hybrid semi-finished products made of materials with significantly diverging melting points (temperature difference > 100 K)