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

在汽车工业轻量化设计中，越来越多的采用不同材料的混合结构来减轻质量。通常使用钢/铝的组合，这在重量和经济之间提供了一个很好的折衷。目前，钢板和铝制大型部件是分开制造的，并在一个额外的操作中连接起来。本研究项目的目的是开发一种综合成形和连接工艺，其中大型铝件和钢板在一个工艺步骤中成形和连接（以下简称混合复合锻造）。该材料粘结是基于锌作为钎焊材料。通过试验确定了钢板与铝件的最佳连接参数。然后，设计了复合复合锻造工艺，构造了成形工具，并通过仿真和实验将最优参数传递到成形过程中。对接头连接质量进行了表征和分析。推导了接头质量与工艺参数之间的关系。研究结果为钢/铝锌复合成形及连接提供了理论依据。这种新方法扩大了生产混合轻质结构的设计可能性。

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.