Contact Temperature Measurements on Hybrid Aluminum–Steel Workpieces in a Cross-Wedge Rolling Process

authored by: Paulina Merkel, Jens Kruse, Mareile Kriwall, Bernd Arno Behrens, Malte Stonis
Abstract: The Collaborative Research Center 1153 is investigating a novel process chain for manufacturing high-performance hybrid components. The combination of aluminum and steel can reduce the weight of components and lead to lower fuel consumption. During the welding of aluminum and steel, a brittle intermetallic phase is formed that reduces the service life of the component. After welding, the workpiece is heated inhomogeneously and hot-formed in a cross-wedge rolling process. Since the intermetallic phase grows depending on the temperature during hot forming, temperature control is of great importance. In this paper, the possibility of process-integrated contact temperature measurement with thin-film sensors is investigated. For this purpose, the initial temperature distribution after induction heating of the workpiece is determined. Subsequently, cross-wedge rolling is carried out, and the data of the thin-film sensors are compared to the temperature measurements after heating. It is shown that thin-film sensors inserted into the tool are capable of measuring surface temperatures even at a contact time of 0.041 s. The new process monitoring of the temperature makes it possible to develop a better understanding of the process as well as to further optimize the temperature distribution. In the long term, knowledge of the temperatures in the different materials also makes it possible to derive quality characteristics as well as insights into the causes of possible process errors (e.g., fracture of the joining zone).
Organisation(s): Institute of Metal Forming and Metal Forming Machines
External Organisation(s): Institut für integrierte Produktion Hannover (IPH)
Type: Article
Journal: Journal of Manufacturing and Materials Processing
Volume: 7
No. of pages: 10
Publication date: 08.2023
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Mechanics of Materials, Mechanical Engineering, Industrial and Manufacturing Engineering
Electronic version(s): https://doi.org/10.3390/jmmp7040130 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{f07e637d37014d7db71b9f88652e0380,
title = "Contact Temperature Measurements on Hybrid Aluminum–Steel Workpieces in a Cross-Wedge Rolling Process",
abstract = "The Collaborative Research Center 1153 is investigating a novel process chain for manufacturing high-performance hybrid components. The combination of aluminum and steel can reduce the weight of components and lead to lower fuel consumption. During the welding of aluminum and steel, a brittle intermetallic phase is formed that reduces the service life of the component. After welding, the workpiece is heated inhomogeneously and hot-formed in a cross-wedge rolling process. Since the intermetallic phase grows depending on the temperature during hot forming, temperature control is of great importance. In this paper, the possibility of process-integrated contact temperature measurement with thin-film sensors is investigated. For this purpose, the initial temperature distribution after induction heating of the workpiece is determined. Subsequently, cross-wedge rolling is carried out, and the data of the thin-film sensors are compared to the temperature measurements after heating. It is shown that thin-film sensors inserted into the tool are capable of measuring surface temperatures even at a contact time of 0.041 s. The new process monitoring of the temperature makes it possible to develop a better understanding of the process as well as to further optimize the temperature distribution. In the long term, knowledge of the temperatures in the different materials also makes it possible to derive quality characteristics as well as insights into the causes of possible process errors (e.g., fracture of the joining zone).",
keywords = "aluminum, cross-wedge rolling, hybrid components, temperature monitoring, thin-film sensors",
author = "Paulina Merkel and Jens Kruse and Mareile Kriwall and Behrens, {Bernd Arno} and Malte Stonis",
note = "Funding Information: This research was funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation)—CRC 1153, subproject B1—252662854. ",
year = "2023",
month = aug,
doi = "10.3390/jmmp7040130",
language = "English",
volume = "7",
journal = "Journal of Manufacturing and Materials Processing",
issn = "2504-4494",
publisher = "MDPI Multidisciplinary Digital Publishing Institute",
number = "4",
}