TY - JOUR

T1 - Process chain for the manufacture of hybrid bearing bushings

AU - Thürer, Susanne Elisabeth

AU - Chugreeva, Anna

AU - Heimes, Norman

AU - Uhe, Johanna

AU - Behrens, Bernd Arno

AU - Maier, Hans Jürgen

AU - Klose, Christian

N1 - Funding Information: The results presented were obtained within the subprojects A1 “Influence of local microstructure on the formability of extruded composite profiles” and B2 “Die forging of coaxially arranged hybrid workpieces” of the Collaborative Research Center 1153 “Process chain to produce hybrid high performance components by Tailored Forming”—252662854, which is supported by the German Research Foundation (DFG).

PY - 2021/4

Y1 - 2021/4

N2 - The current study presents a novel Tailored Forming process chain developed for the production of hybrid bearing bushings. In a first step, semi-finished products in the form of locally reinforced hollow profiles were produced using a new co-extrusion process. For this purpose, a modular tool concept was developed in which a steel tube made of a case-hardening steel, either C15 (AISI 1015) or 20MnCr5 (AISI 5120), is fed laterally into the tool. Inside the welding chamber, the steel tube is joined with the extruded aluminum alloy EN AW-6082. In the second step, sections from the compound profiles were formed into hybrid bearing bushings by die forging. In order to set the required forming temperatures for each material—aluminum and steel—simultaneously, a tailored heating strategy was developed, which enabled successful die forging of the hybrid workpiece to the desired bearing bushing geometry. Using either of the case-hardening steels in combination with aluminum, this novel process chain made it possible to produce intact hybrid bearing bushings, which showed both macroscopically and microscopically intimate material contact inside the compound zone.

AB - The current study presents a novel Tailored Forming process chain developed for the production of hybrid bearing bushings. In a first step, semi-finished products in the form of locally reinforced hollow profiles were produced using a new co-extrusion process. For this purpose, a modular tool concept was developed in which a steel tube made of a case-hardening steel, either C15 (AISI 1015) or 20MnCr5 (AISI 5120), is fed laterally into the tool. Inside the welding chamber, the steel tube is joined with the extruded aluminum alloy EN AW-6082. In the second step, sections from the compound profiles were formed into hybrid bearing bushings by die forging. In order to set the required forming temperatures for each material—aluminum and steel—simultaneously, a tailored heating strategy was developed, which enabled successful die forging of the hybrid workpiece to the desired bearing bushing geometry. Using either of the case-hardening steels in combination with aluminum, this novel process chain made it possible to produce intact hybrid bearing bushings, which showed both macroscopically and microscopically intimate material contact inside the compound zone.

KW - Co-extrusion

KW - Die forging

KW - Hybrid bulk metal component

KW - Tailored forming

UR - http://www.scopus.com/inward/record.url?scp=85101074266&partnerID=8YFLogxK

U2 - 10.1007/s11740-021-01028-4

DO - 10.1007/s11740-021-01028-4

M3 - Article

AN - SCOPUS:85101074266

VL - 15

SP - 137

EP - 150

JO - Production Engineering

JF - Production Engineering

SN - 0944-6524

IS - 2

ER -