Component Optimization by Forging of Composite Aluminum Extrusions

多材料组件的益处表现为所使用的单一材料的特定材料的优势。这些组件特别适用于当前的需求配置文件。本合作项目的目标是研究连续型钢铝件生产的复合挤压和后续锻造的工艺链，研究了采用混合挤压和锻造相结合的方法制造部分和连续增强的零件，并成功地研究了工艺之间的相互作用。在挤压领域，可以实现对旋转对称、部分复合挤压的稳定过程控制，并实现对增强元件位置的预先计算。可以看出，加固非旋转对称型材是可能的。论证了部分挤压与连续挤压相结合的工艺可行性。针对部分和连续增强的原材料锻件，在有限元模拟和实验的基础上，优化了铝半成品在材料流动过程中增强元件的位置变化。根据所描述的结果，在第二应用阶段，通过增加增强元件分布的复杂程度来定义和扩展可能的产品范围。从调整增强元件在复合材料部分中的局部适应分布的最优目标出发，得出以下方面的考虑：-非轴对称截面局部增强半成品的热挤压-非旋转对称增强元件的埋入-具有增强元件偏心位置的型材的制造-锻造区域中连续和不连续复合挤压的组合的工艺设计，将讨论以下问题：-锻造过程中材料流动的分析和控制--锻件的几何形状的设计--增强半成品铝件的不均匀预热以控制成形性增强元素两个过程的重要里程碑是考虑增强元素在部件中的形状和位置的相应工艺窗口的隔离和随后的组合。这也包括粘合区和组件属性的表征

The benefit of multi-material components is characterized by the material-specific advantages of the used mono materials. The components are specifically adapted to the current requirement profiles. The object of this cooperation project is to study the process chain of compound extrusion and subsequent forging for the production of continuously steel-reinforced aluminum components.The manufacturing of partially and continuously reinforced components by combining hybrid extrusion and forging was investigated and the interactions between the processes were studied successfully. In the field of extrusion, a stable process control for rotationally symmetrical, partial composite extrusion could be realized and a pre-calculation of the reinforcing element position was achieved. It could be shown that it is possible to reinforce non-rotationally symmetrical profiles. Furthermore, the feasibility of the process combination of partial and continuous composite extrusion was demonstrated. For forging of partially and continuously reinforced raw parts, the change in position of the reinforcing elements during the material flow in the semi-finished aluminum parts was optimized on the basis of FEM simulations and experiments. In the following the influences on the joining zone quality were identified and qualified.Based on the results described, the possible product range shall be defined and extended in the second application phase by increasing the degree of complexity of the distribution of the reinforcing elements. From the superior target of adjusting a locally adapted distribution of the reinforcing elements in the composite part the following aspects are derived to be considered:- Hot extrusion of locally reinforced semi-finished products with non axially-symmetric cross section- Embedding of non-rotationally symmetric reinforcing elements- Manufacturing of profiles with excentric position of the reinforcing elements- Process design of the combination of continuous and discontinuous composite extrusion In the area of forging, the following issues will be addressed:- Analysis and control of the material flow in forging- Design of the geometry of the forging slug- Inhomogeneous preheating of the reinforced semi-finished aluminum parts for controlling of the formability the reinforcing elementsImportant milestones for both processes are the isolation and subsequent combination of corresponding process windows that consider the shape and the position of the reinforcing elements in the component. This also includes the characterization of the bonding zone and the component properties