Hybrid compound forging for joining aluminum bulk elements and steel sheet metals

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In automobile industry lightweight design more and more hybrid structures made of different materials are used to reduce mass. Often a combination of steel/aluminum is used, which provides a good compromise between weight and economy. Steel sheets and aluminum massive parts are currently manufactured separately and joined in an additional operation.The aim of this research project is to develop an integrated forming and joining process in which a massive aluminum part and a steel sheet are formed and joined in one process step (hereinafter referred to as a hybrid compound forging). The material bond is based on zinc as brazing material. Therefore optimal joining-parameters between the steel sheet and the aluminum part are determined through experiments. Afterwards, a hybrid compound forging process is designed, forming tools are constructed and the optimal parameters are transferred to the forming process by simulation and experiment. The quality of the joint connection is characterized and analyzed. The relationship between joint quality and process parameters is derived.The results of the research provide the basics for combined forming and joining of steel/aluminum using zinc. This new method expands the design possibilities for the production of hybrid lightweight structures.