Influence of Duplex- tool coatings on the thermomechanical tribological properties during friction spinning of AW 6060 and the generation of a numerical simulation of the friction spinning process

在第一个资助期的基础上，该后续项目涉及对AW 6060成形过程中摩擦和粘附过程的摩擦挤压过程进行更详细的分析。在这种情况下，为摩擦旋压工具开发了双涂层系统，其目的是优化工具-工件系统中的热流，并最大限度地减少工具磨损并提高工件的表面质量。因此，更深入地了解TiBN-PVD薄层的氧化物陶瓷热障涂层（TBC）的粘附机制是通过应用粘附促进金属夹层。分析了摩擦旋压过程中TiBN表层对摩擦和附着性能的影响。该双层涂层集成了大气等离子喷涂的Al 2 O3或ZrO 2 - 8 Y2 O3热障涂层和使用冷气体喷涂的NiCr、Ti或Cr金属化它们的表面。金属化的目的是完全覆盖TBC的表面附近的孔，从而降低粗糙度，以便通过PVD实现TiBN的近净形沉积。在AW 6060成形过程中，刀具的表面粗糙度与粘着磨损密切相关。这些方法包括应用开发的双层涂层，除了应用凹槽和润滑外，还可以改变接触面积的大小。因此，工艺策略是要得到优化的热流，以减少粘附wear.The第一个资助期的结果证实了摩擦的依赖性，特别是对温度和相对速度。此外，摩擦力取决于法向应力。由于摩擦纺纱涉及高温、相对速度和正常压力值，第二个供资期的目标是确定真实的工艺条件下的摩擦特性，以获得可靠的结果。为此，将准备一个实验装置，其中压缩测试集成在摩擦纺纱装置中，从而工具板移动到旋转AW 6060管上并开始塑性变形。法向力将直接测量，而剪切力将根据扭矩测量值计算。所得的力将用于深入了解摩擦纺纱过程中的摩擦力，并推导出具有代表性的摩擦纺纱模型。所获得的摩擦值将被整合到热-机械有限元模拟模型中，以描述摩擦纺纱过程。仿真模型，然后验证与实验值的温度，力和几何特征。

Based on the first funding period, this follow-up project is concerned with the analysis of the friction-pressing process in more detail with regard to the friction and the adhesion processes during the forming of AW 6060. In this context, duplex coating systems are developed for the friction-spinning tools, which aim to optimize the heat flow in the tool-workpiece system and to minimize tool wear and increase the surface quality of the workpieces. Thus, a deeper understanding of the adhesion mechanisms of TiBN-PVD thin layers on oxide-ceramic thermal barrier coatings (TBC) is generated through the application of adhesion-promoting metallic interlayers. The interactions of the TiBN top layer on the friction and adhesion properties during the friction-spinning process are then analyzed. The duplex coating integrates atmospheric plasma sprayed Al2O3 or ZrO2-8Y2O3 TBCs and a metallization of their surfaces with NiCr, Ti or Cr using cold gas spraying. The aim of the metallization is to completely cover the surface-near pores of the TBC and thus to reduce the roughness in order to achieve a near-net-shape deposition of TiBN by means of PVD. The surface roughness of the tool is correlated particularly with the adhesive wear during the forming of AW 6060.Furthermore, approaches will be analyzed to optimize the tool performance. These approaches include the application of the developed duplex coatings, varying the contact area size in addition to applying grooves and lubrication. Consequently, process strategies are to be derived to optimize the heat flow and to reduce the adhesive wear.The results of the first funding period confirmed the dependency of friction especially on temperature and relative velocity. Furthermore, is friction dependent on normal stress. Due to the fact that friction spinning involves high temperatures, relative velocities and normal pressure values, the target of the second funding period is to characterize friction under real process conditions to obtain reliable results. For this purpose, an experimental setup will be prepared, in which a compression test is integrated in the friction-spinning setup, whereby a tool plate moves onto the rotating AW 6060 tube and initiates plastic deformation. The normal forces are to be measured directly whereas the shear forces will be calculated from torque measurements. The obtained forces will then be used to gain a solid understanding of the friction in this process and to derive representable friction model for friction-spinning. The friction values obtained will consequently be integrated in the thermo-mechanical FEM-simulation model to depict the friction spinning process. The simulation model is then validated with experimental values in terms of temperature, force and geometric features.