SFB 1153: Process Chain for Manufacturing of Hybrid High Performance Components by Tailored Forming

合作研究中心(CRC)1153旨在确定基于新的工艺链的混合块状金属部件的潜力，并开发必要的制造工艺。与传统的混合块状金属部件的制造和生产工艺不同，连接过程仅在成形过程中或在制造链的末端进行，CRC使用在成形过程之前联接的半成品。这使得能够生产比单一材料部件更好地满足其内部不同结构和功能领域的本地要求的部件。通过在部件中组合不同的材料，可以减轻部件的重量或降低部件的成本，同时通过本地使用轻质材料或将其与高质量合金相结合来保持或提高性能。与现有的制造工艺相比，定制成型工艺链中半成品的简单几何形状便于处理和可靠地生产粘合连接区。通过在后续成形过程中具体控制材料流动，还可以影响所产生的接合区几何形状，这在传统的接合工艺中是不可行的。成形过程中的热机械影响也改善了连接区的质量。CRC1153的创新方法包括通过建立必要的工艺指南和得出具体的法律，对从半成品到可用部件的制造和开发过程进行完整的观察。到目前为止开发的定制成形工艺的技术准备程度将在第三个供资期间进一步提高。为此目的，除其他外，将提高单个和整个过程链的稳健性，扩大定性选择和建模方法。分散开发的工艺的物理和数字合并将能够在系列锻造试验中验证工艺链的稳健性。同时，附加测量技术的集成以及相关工艺数据的一致获取和提供允许在单个工艺步骤之外推导控制算法，从而重复地增加用于生产混合高性能部件的工艺参数空间。为了能够将开发的创新转化为工业实践，需要对开发的技术的经济和生态附加值进行评估。为此，以前的经济评估方法将考虑生态影响变量，这些方法与技术改进一起证明了新技术的总体潜力。

The Collaborative Research Center (CRC) 1153 aims at identifying the potential of hybrid bulk-metal components based on a novel process chain and at developing the necessary manufacturing processes. In contrast to the conventional manufacturing and production processes for hybrid bulk-metal components where the joining process only takes place during forming or at the end of the manufacturing chain, the CRC uses semi-finished products that are joined before the forming process. This allows for the production of components that meet the local requirements of different structural and functional areas within themselves much better than mono-material components. By combining different materials within a component, the weight or the costs of the component can be reduced while maintaining or improving performance either by the local use of lightweight materials or by combining it with high-quality alloys. In comparison with existing manufacturing processes, the simple geometry of the semi-finished products in the tailored forming process chain facilitates handling and a reliable production of a cohesive joining zone. By means of specifically controlling the material flow during the subsequent forming, the resulting joining zone geometry can be influenced as well, which is currently not feasible in conventional joining processes. The thermomechanical influence during forming also improves the quality of the joining zones. The innovative approach of the CRC 1153 includes an integral view of the manufacturing and development process from the semi-finished workpiece to the usable component by establishing the necessary process guidelines and deriving specific laws. The technology-readiness level of tailored forming processes developed to date is to be further increased in the third funding period. To this end, the robustness of the individual and overall process chain is to be increased and the characterisation options and modelling approaches expanded, among other things. The physical and digital consolidation of the decentrally developed processes will enable the verification of the robustness of the process chain in serial forging tests. At the same time, the integration of additional measurement technology as well as the consistent acquisition and provision of relevant process data permits the derivation of control algorithms beyond the individual process steps, thus reproducibly increasing the process parameter space for the production of hybrid high-performance components. In order to be able to transfer the developed innovations into industrial practice, evaluation possibilities are required to assess the economic and ecological added value of the developed technology. For this purpose, ecological influencing variables will be taken into account in previous economic evaluation approaches, which, together with the technological enhancements, prove the overall potential of the new technology.