Energy efficient manufacturing chain for advanced bainitic forging steels based on thermo-mechanical processing

基于热机械加工的先进贝氏体锻钢节能制造链

• 批准号: 327887503
• 负责人: Dr.-Ing. Jérémy Epp
• 金额: --
• 依托单位: PPGE3M
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2017
• 资助国家: 德国
• 起止时间: 2016-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/327887503?language=en
• 关键词: Energy; efficient; manufacturing; chain; advanced

The forging sector for the automotive industry nowadays seeks for more resource efficient processes. In order to reduce energy consumption with a possibility of significant cost reduction, this project aims at developing innovative process chains for new generation bainitic steels with continuous direct cooling after forging, replacing the traditional hardening and tempering processes. In the first phase of the project, new knowledge on thermomechanical processing of three advanced bainitic steels was generated, which allowed the definition of process window for these steels. The main results indicate great potential for application of these materials by means of thermomechanical routes on an industrial scale, which, in addition to reducing energy consumption, also make it possible to obtain a bainitic microstructure with improved mechanical properties. The investigations also enabled the further development and use of high impact scientific techniques such as in situ analyses using eddy current sensor and high energy synchrotron XRD as well as the realization of preliminary forging on an industrial scale, thus combining the scientific and technological aspects. In this framework, several effects and open questions were identified, which still need to be clarified. The second stage of the project has therefore as its main objective the improvement and transfer of the acquired knowledge to robust strategies for industrial production of machine components, in the sense of actual trends towards industry 4.0, based on sensor controlled manufacturing. The working plan is focused on three main areas: thermomechanical processing of components, post-processing steps and inspection of mechanical properties. Extensive physical and FEM-simulation as well as industrial scale forging experiments will allow the development of suitable treatment strategies for these steels. For this, further development and implementation of Eddy-current sensors combined with a controlled cooling unit will be realized in real thermomechanical process. The processed components will be characterized concerning the final microstructure and mechanical properties. The combination with additional surface hardening treatments will be further evaluated, as induction hardening, plasma nitriding and deep rolling/ shot peening. The achieved mechanical properties will then be intensively analyzed in terms of strength and ductility but also regarding the fatigue properties. In particular, the influence of the amount and stability of the retained austenite will be investigated, since it is seen as one of the major carrier for improved mechanical properties.

如今，汽车行业的锻造部门正在寻求更高效的工艺。为了降低能源消耗，同时大幅降低成本，该项目旨在开发新一代贝氏体钢的创新工艺链，采用锻造后连续直接冷却，取代传统的淬火和回火工艺。在该项目的第一阶段，产生了三种先进贝氏体钢的热机械加工的新知识，这使得这些钢的工艺窗口的定义。主要结果表明，这些材料的应用潜力很大，通过热机械路线在工业规模上，其中，除了减少能源消耗，也使人们有可能获得贝氏体显微组织与改善的机械性能。这些研究还使进一步开发和使用高影响力的科学技术成为可能，例如使用涡流传感器和高能同步加速器XRD进行现场分析，以及实现工业规模的初步锻造，从而将科学和技术方面结合起来。在这一框架内，确定了若干影响和未决问题，但仍需加以澄清。因此，该项目的第二阶段的主要目标是将所获得的知识改进和转移到机器部件工业生产的稳健战略中，这是基于传感器控制制造的工业4.0的实际趋势。工作计划主要集中在三个方面：部件的热机械加工、后处理步骤和机械性能检查。广泛的物理和有限元模拟以及工业规模的锻造实验将允许为这些钢开发合适的处理策略。为此，涡流传感器与受控冷却单元相结合的进一步开发和实施将在真实的热机械过程中实现。将对加工后的部件进行最终微观结构和机械性能表征。将进一步评估与其他表面硬化处理的组合，如感应淬火，等离子渗氮和深滚/喷丸。然后将从强度和延展性以及疲劳性能方面对所获得的机械性能进行深入分析。特别是，将研究残余奥氏体的量和稳定性的影响，因为它被视为改善机械性能的主要载体之一。