Compound forging of hybrid powder-solid-parts made of steel and aluminum

本项目将从根本上检验粉末冶金和复合锻造工艺组合在钢铝混合构件生产中的适用性，并确定工艺极限。由于混合原始构件需要不均匀加热，在复合成形过程中，当铝接触钢时，可能会发生铝芯局部熔化。这确保了在混合部件的连接区域中形成金属间相，其中金属间相接缝的厚度是整体结合强度的标准。本研究项目的目的是通过在连接区域中添加合金元素来影响复合锻造过程中金属间相的形成。为此目的，混合原始部件的铝芯通过粉末冶金在表面中或在接合区域中制造有梯度结构。随后，在复合锻造过程中，混合粉末-固体部件将被成形连接，将定量分析各种合金元素和边界层厚度对金属间相接缝厚度的影响。用于生产钢和铝制成的混合部件的冶金和复合锻造是通过以下方式制造功能部件的有前途的方法：应用节省资源的工艺步骤。

In the proposed project, the suitability of the process combination of powder-metallurgy and compound forging for the production of hybrid steel-aluminum components will be examined fundamentally and the process limits will be identified.Due to the required inhomogeneous heating of the hybrid raw part, a local melting of the aluminum core may occur during the compound forming process when aluminum contacts steel. This ensures the formation of intermetallic phases in the joining zone of the hybrid components, where the thickness of the intermetallic phase seam is a criterion for the global bonding strength.The aim of this research project is to influence the intermetallic phase formation during the compound forging process by adding alloying elements in the joining zone. For this purpose, the aluminum core of the hybrid raw part is manufactured with a graded structure in the surface, respectively in the joining zone, by powder metallurgy. Subsequently upon the compound forging process, hybrid powder-solid-parts will be form-joined, firmly-bonded-joined and nonpositive-joined and the influence of various alloying elements and boundary layer thicknesses on the intermetallic phase seam thickness will be quantified.The use of the process combination of powder-metallurgy and compound forging for the production of hybrid components made of steel and aluminum is a promising method to manufacture functional parts by applying resource-saving process steps.