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Investigation of the coating thickness of plasma-transferred arc deposition welded and cross wedge rolled hybrid parts


Most of today’s technical parts and components are made of monolithic materials. These mono-material components produced in established production processes reach their limits due to their respective material characteristics. Thus, a significant increase in production quality and efficiency can only be achieved by combining different materials in one part. Bulk forming of previously joined semi-finished products to net shape hybrid components that consist of two different materials is a promising method to produce parts with locally optimized characteristics. This new production process chain offers a number of advantages compared to conventional manufacturing technologies. Examples are the production of specific load-adapted forged parts with a high level of material utilization, an improvement of the joining zone caused by the following forming process and an easy to implement joining process due to the simple geometries of the semi-finished products. This paper describes the production process of hybrid steel parts, produced by combining a plasma-transferred arc deposition welding process with a subsequent cross wedge rolling process. This innovative process chain enables the production of hybrid parts. To evaluate the developed process chain, coating thickness of the billet is analysed before and after cross wedge rolling. It could be shown, that the forming process leads to an improvement of the coating, meaning a more homogeneous distribution along the main axis.

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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 subprojects A4 and B1. The authors would like to thank the German Research Foundation (DFG) for the financial and organisational support of this project.

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Correspondence to Thoms Blohm.

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Blohm, T., Mildebrath, M., Stonis, M. et al. Investigation of the coating thickness of plasma-transferred arc deposition welded and cross wedge rolled hybrid parts. Prod. Eng. Res. Devel. 11, 255–263 (2017).

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  • Process chain
  • Plasma-transferred arc deposition welding
  • Hybrid parts
  • Cross wedge rolling