Characterization and modeling of intermetallic phase formation during the joining of aluminum and steel in analogy to co-extrusion

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Original languageEnglish
Article number1582
Pages (from-to)1-16
Number of pages16
JournalMetals
Volume10
Issue number12
Publication statusPublished - 26 Nov 2020

Abstract

The reinforcement of light metal components with steel allows to increase the strength of the part while keeping the weight comparatively low. Lateral angular co-extrusion (LACE) offers the possibility to produce hybrid coaxial profiles consisting of steel and aluminum. In the present study, the effect of the process parameters temperature, contact pressure and time on the metallurgical bonding process and the development of intermetallic phases was investigated. Therefore, an analogy experiment was developed to reproduce the process conditions during co-extrusion using a forming dilatometer. Based on scanning electron microscopy analysis of the specimens, the intermetallic phase seam thickness was measured to calculate the resulting diffusion coefficients. Nanoindentation and energy dispersive X-ray spectroscopy measurements were carried out to determine the element distribution and estimate properties within the joining zone. The proposed numerical model for the calculation of the resulting intermetallic phase seam width was implemented into a finite element (FE) software using a user-subroutine and validated by experimental results. Using the subroutine, a numerical prediction of the resulting intermetallic phase thicknesses is possible during the tool design, which can be exploited to avoid the weakening of the component strength due to formation of wide intermetallic phase seams.

Keywords

    Aluminum-steel compound, Co-extrusion, Intermetallic phases, Nanoindentation, Tailored forming

ASJC Scopus subject areas

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Characterization and modeling of intermetallic phase formation during the joining of aluminum and steel in analogy to co-extrusion. / Behrens, Bernd Arno; Maier, Hans Jürgen; Klose, Christian et al.
In: Metals, Vol. 10, No. 12, 1582, 26.11.2020, p. 1-16.

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title = "Characterization and modeling of intermetallic phase formation during the joining of aluminum and steel in analogy to co-extrusion",
abstract = "The reinforcement of light metal components with steel allows to increase the strength of the part while keeping the weight comparatively low. Lateral angular co-extrusion (LACE) offers the possibility to produce hybrid coaxial profiles consisting of steel and aluminum. In the present study, the effect of the process parameters temperature, contact pressure and time on the metallurgical bonding process and the development of intermetallic phases was investigated. Therefore, an analogy experiment was developed to reproduce the process conditions during co-extrusion using a forming dilatometer. Based on scanning electron microscopy analysis of the specimens, the intermetallic phase seam thickness was measured to calculate the resulting diffusion coefficients. Nanoindentation and energy dispersive X-ray spectroscopy measurements were carried out to determine the element distribution and estimate properties within the joining zone. The proposed numerical model for the calculation of the resulting intermetallic phase seam width was implemented into a finite element (FE) software using a user-subroutine and validated by experimental results. Using the subroutine, a numerical prediction of the resulting intermetallic phase thicknesses is possible during the tool design, which can be exploited to avoid the weakening of the component strength due to formation of wide intermetallic phase seams.",
keywords = "Aluminum-steel compound, Co-extrusion, Intermetallic phases, Nanoindentation, Tailored forming",
author = "Behrens, {Bernd Arno} and Maier, {Hans J{\"u}rgen} and Christian Klose and Hendrik Wester and Th{\"u}rer, {Susanne Elisabeth} and Norman Heimes and Johanna Uhe",
note = "Funding Information: Acknowledgments: The results presented in this paper were obtained within the Collaborative Research Center 1153 “Process chain to produce hybrid high performance components by Tailored Forming” in the subproject A01, funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation)—252662854. The authors thank the German Research Foundation (DFG) for their financial support of this project. ",
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AU - Behrens, Bernd Arno

AU - Maier, Hans Jürgen

AU - Klose, Christian

AU - Wester, Hendrik

AU - Thürer, Susanne Elisabeth

AU - Heimes, Norman

AU - Uhe, Johanna

N1 - Funding Information: Acknowledgments: The results presented in this paper were obtained within the Collaborative Research Center 1153 “Process chain to produce hybrid high performance components by Tailored Forming” in the subproject A01, funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation)—252662854. The authors thank the German Research Foundation (DFG) for their financial support of this project.

PY - 2020/11/26

Y1 - 2020/11/26

N2 - The reinforcement of light metal components with steel allows to increase the strength of the part while keeping the weight comparatively low. Lateral angular co-extrusion (LACE) offers the possibility to produce hybrid coaxial profiles consisting of steel and aluminum. In the present study, the effect of the process parameters temperature, contact pressure and time on the metallurgical bonding process and the development of intermetallic phases was investigated. Therefore, an analogy experiment was developed to reproduce the process conditions during co-extrusion using a forming dilatometer. Based on scanning electron microscopy analysis of the specimens, the intermetallic phase seam thickness was measured to calculate the resulting diffusion coefficients. Nanoindentation and energy dispersive X-ray spectroscopy measurements were carried out to determine the element distribution and estimate properties within the joining zone. The proposed numerical model for the calculation of the resulting intermetallic phase seam width was implemented into a finite element (FE) software using a user-subroutine and validated by experimental results. Using the subroutine, a numerical prediction of the resulting intermetallic phase thicknesses is possible during the tool design, which can be exploited to avoid the weakening of the component strength due to formation of wide intermetallic phase seams.

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