Massivumformung

• Forging of α+ß titanium alloys with steel casing

  Titanium alloy products are currently mainly manufactured by machining. However, this leads to relatively large material losses. An alternative production method is the die forging process, whereby the forged titanium is more durable than the machined workpiece. Isothermal forging, which takes place in an inert gas atmosphere to prevent reactions with gases in the air atmosphere, is state of the art. Isothermal forging is therefore difficult to implement in terms of plant and process technology. The use of a steel capsule around the titanium alloy is intended to enable die forging without a protective gas atmosphere and isothermal forging with a low machining volume in order to ensure wider applicability.

  Year: 2023

  Funding: Deutsche Forschungsgemeinschaft (DFG) - Projektnummer 461918196
• Transparent AI-supported process modeling in drop forging

  The goal of the project is to optimize a die forging process through the use of an AI data model for process modeling. It addresses the challenge of understanding complex interactions between various process parameters. By means of automated data collection, high-quality data are gathered to train the AI model, which will subsequently be capable of recognizing patterns and making predictions about quality characteristics based on process parameters.

  Year: 2022

  Funding: Deutsche Forschungsgemeinschaft (DFG) – SPP2422
• Highly heat-resistant tool surface layers by extending the tailored forming technology to hot solid forming tools

  In this transfer project, a forming process chain for the production of hybrid forming tools is to be analyzed and developed. Tailored forming technology is used to provide tools made from hot-working steel as the base material with a highly heat-resistant Inconel surface layer. These should have a high resistance to thermomechanical failure patterns and contribute to a significant increase in the service life of tools in hot forging.

  Year: 2022

  Funding: SFB 1153 – Transferprojekt T03
• ERProFit - Energy and resource efficient production - Low-oxygen forging through retrofitting existing forging systems

  The focus of the project is to prevent scale formation in the process of hot forging by taking place in a low-oxygen atmosphere, which prevents oxidation of the workpiece surface. This results in enormous potential for CO2 savings along the entire value chain, as no unnecessary loss of material occurs due to the lack of scale. Furthermore, natural resources are conserved through the more efficient use of raw materials.

  Year: 2021

  Funding: BMWi - Bundesministeriums für Wirtschaft und Energie
• Use of additively manufactured forging dies with contour-adapted internal cooling

  Forging dies are subjected to high stress, which leads to wear and reduced tool life. The thermal tool load is essentially due to the contact of the forging die with the heated parts. As part of this research project, complex internal cooling channels are introduced into forging dies using additive manufacturing processes in order to temper them from the inside and counteract thermal tool damage.

  Year: 2020

  Funding: Förderung: Forschungsvereinigung der Arbeitsgemeinschaft der Eisen und Metall verarbeitenden Industrie e.V. (AVIF) – Fördernummer AVIF A 318
• Novel combination of processes for the production of titanium aluminide-based components in an oxygen-free atmosphere

  Titanium aluminides (TiAl) are among the oxygen-affinous materials whose structural development and thus physical and technological properties depend heavily on the oxygen content. Due to their high heat resistance and very low density, they have high potential for application in the automotive, aerospace and aerospace industries. However, TiAl is difficult to process due to its brittleness, so that isothermal forging or hot isostatic pressing (HIP), which are complex in terms of process and system technology, are primarily used. Conventional powder metallurgical production, using die pressing and sintering, has so far led to inadequate results in terms of relative density as well as technological and physical properties due to impurities.

  Year: 2020

  Funding: Förderung: Deutsche Forschungsgemeinschaft (DFG) – SFB 1368 - Fördernummer 394563137
• Determination of the deformation capacity and the resulting component properties during extrusion of serially arranged hybrid semi-finished products

  The subproject B3 deals with the extrusion of friction-welded hybrid semi-finished products made of steel-aluminum, steel-nickel-based alloy and steel-steel. During friction welding, different geometries of the end face are used in order to achieve a force and positive connection in addition to the material connection. Extrusion involves a variation of the extrusion process. To increase the stress caused by forming, a hollow shaft will serve as a demonstrator, which will be manufactured using various extrusion processes.

  Year: 2019

  Funding: Deutsche Forschungsgemeinschaft (DFG) – SFB 1153 – B3 – Fördernummer 252662854