A Numerical Study on Co-Extrusion to Produce Coaxial Aluminum-Steel Compounds with Longitudinal Weld Seams

authored by: Bernd Arno Behrens, Christian Klose, Alexander Chugreev, Norman Heimes, Susanne Elisabeth Thürer, Johanna Uhe
Abstract: The use of lightweight materials is one possibility to limit the weight of vehicles and to reduce CO₂ emissions. However, the mechanical properties and weight-saving potential of mono-materials are limited. Material compounds can overcome this challenge by combining the advantages of different materials in one component. Lateral angular co-extrusion (LACE) allows the production of coaxial semi-finished products consisting of aluminum and steel. In this study, a finite element model of the LACE process was built up and validated by experimental investigations. A high degree of agreement between the calculated and experimentally determined forces, temperatures, and the geometrical shape of the hybrid profiles was achieved. In order to determine suitable parameters for further extrusion experiments, the influence of different process parameters on material flow and extrusion force was investigated in a numerical parametric study. Both the temperature and extrusion ratio showed a significant influence on the occurring maximum extrusion force as well as the material flow inside the LACE tool. The maximum force of 2.5 MN of the employed extrusion press was not exceeded. An uneven material flow was observed in the welding chamber, leading to an asymmetric position of the steel rod in the aluminum matrix.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Institute of Materials Science
Type: Article
Journal: Metals
Volume: 8
ISSN: 2075-4701
Publication date: 09.2018
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: General Materials Science
Electronic version(s): https://doi.org/10.3390/met8090717 (Access: Open)
https://doi.org/10.15488/4221 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{75fa04289f10447ebe4b4e483e77790c,
title = "A Numerical Study on Co-Extrusion to Produce Coaxial Aluminum-Steel Compounds with Longitudinal Weld Seams",
abstract = "The use of lightweight materials is one possibility to limit the weight of vehicles and to reduce CO2 emissions. However, the mechanical properties and weight-saving potential of mono-materials are limited. Material compounds can overcome this challenge by combining the advantages of different materials in one component. Lateral angular co-extrusion (LACE) allows the production of coaxial semi-finished products consisting of aluminum and steel. In this study, a finite element model of the LACE process was built up and validated by experimental investigations. A high degree of agreement between the calculated and experimentally determined forces, temperatures, and the geometrical shape of the hybrid profiles was achieved. In order to determine suitable parameters for further extrusion experiments, the influence of different process parameters on material flow and extrusion force was investigated in a numerical parametric study. Both the temperature and extrusion ratio showed a significant influence on the occurring maximum extrusion force as well as the material flow inside the LACE tool. The maximum force of 2.5 MN of the employed extrusion press was not exceeded. An uneven material flow was observed in the welding chamber, leading to an asymmetric position of the steel rod in the aluminum matrix.",
keywords = "Aluminum-steel compound, Co-extrusion, FEM, Tailored forming",
author = "Behrens, {Bernd Arno} and Christian Klose and Alexander Chugreev and Norman Heimes and Th{\"u}rer, {Susanne Elisabeth} and Johanna Uhe",
note = "Funding information: This research was funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) grant number 252662854. The APC was funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation). The results presented in this paper were obtained within the Collaborative Research Centre 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 flow curves presented in this paper were obtained in cooperation with subproject C1 of the Collaborative Research Centre 1153. The authors thank the German Research Foundation (DFG) for their financial support of this project.",
year = "2018",
month = sep,
doi = "10.3390/met8090717",
language = "English",
volume = "8",
journal = "Metals",
issn = "2075-4701",
publisher = "Multidisciplinary Digital Publishing Institute",
number = "9",
}