Hybrid interaction during and after thixoforging of multi material systems

在能源和资源成本不断上升的时代，提高生产和应用效率是开发和优化制造工艺的重要技术驱动力。因此，通过在局部优化和负载情况下适应的混合部件的生产中减轻重量，可以有效地节省能源和资源。本研究项目的目的是开发具有金属-金属结合的混合部件的触变成形锻造工艺。因此，在不同金属材料之间的触变锻造过程期间和之后发生的金属间相的表征是一个主要的研究课题。在第一个供资期内，重点是开发两种工艺路线以及待生产的金属化合物的具体设计，同时考虑到不同材料的连接和过渡区发生的相互作用机制。在第一个资助期内，最初在真实的成形试验过程中生产简单的盘部件，而在第二个资助期内，将实施具有更复杂流动路径的非旋转对称部件几何形状，以便更深入地了解两种不同半液态金属合金同时成形期间的流动行为。此外，在第一个资助期内，混合半成品的触变成形模拟研究出现的不足之处，将由第二个资助期内的拟议研究工作弥补。在第二个资助期内，我们会致力达致下列科学目标：- 通过触变锻造研究分级半成品的接头成形，同时考虑复杂的流动路径，并通过FEM模拟对材料流动进行建模-开发有限元模拟的数值模型，以便通过不同半固态金属合金的流动曲线描述触变材料特性-研究加热过程中和成形过程后不同材料之间的材料转变-确定混合部件的功能特性，特别是板条箱连接区域的机械特性-将获得的知识转移到由具有显著不同熔点的材料制成的混合半成品（温差> 100 K）

In times of rising energy and resource costs, improvement of efficiency in production and application is an important technological driver for development and optimization of manufacturing processes. Thereby, an effective input for saving energy and the conservation of resources is contributed by weight reductions within the production of locally optimized and on load cases adapted hybrid components.The aim of this research project is to develop the process for thixoforging of hybrid components with metal-to-metal bonds. Thereby, the characterization of the intermetallic phases occurring both during and after the thixoforging process between the different metallic materials is a major research topic. In the first funding period, the focus was on the development of two process routes as well as the specific design of the metallic compounds to be produced, taking into account the interaction mechanisms occurring in the joining and transition zones of the different materials. While in the first funding period, simple disk components were initially produced in the course of the real forming tests, a non-rotationally symmetrical component geometry with more complex flow paths is to be implemented in the second funding period in order to gain a deeper understanding of the flow behaviour during simultaneous forming of two different semi-liquid metal alloys. Furthermore, the deficits that occured in the simulative illustration of thixoforging of hybrid semi-finished products during the first funding period are to be remedied by the proposed research work in the second funding period.The following scientific objectives will be pursued within the second funding period:- Investigations of the joint forming of graded semi-finished products by thixoforging taking into account complex flow paths and modelling of the material flow by means of FEM simulation- Development of a numerical model for FEM simulation in order to describe thixotropic material properties by flow curves of different semi-solid metal alloys- Investigations of the material transitions between the different materials during heating and after the forming process- Determination of the functional properties of the hybrid components and in particular the mechanical properties of the crated joining zones- Transfer of the knowledge gained to hybrid semi-finished products made of materials with significantly diverging melting points (temperature difference > 100 K)