Abstract
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 and an impact on the joining zone caused by the following forming process. This paper describes the production process of serially arranged hybrid steel parts, produced by combining a laser welding process with a subsequent cross wedge rolling process. The presented results are only a first approach in order to get first insights in the forming behaviour of laser welded and cross wedge rolled parts. The investigated material combination is C22 (1.0402) and 20MnCr5 (1.7147). This innovative process chain enables the production of hybrid parts. To evaluate the developed process chain, the weld and the joining zone is analysed before and after cross wedge rolling. Main results are that the joining process using laser welding enables a strong bonding between the two materials with a higher hardness in the joining zone than for the individual materials. After the forming process, the bonding of the joining zone is still present, while the hardness decreased but remains higher than of the materials themselves.
This is a preview of subscription content, log in to check access.













References
- 1.
Seffer O et al (2014) Laser-GMA hybrid welding of API 5L X70 with 23mm plate thickness using 16kW disk laser and two GMA welding power sources. J Laser Appl 26:042005. https://doi.org/10.2351/1.4895638
- 2.
Feng J et al (2017) Understanding and elimination of process defects in narrow gap multi-pass fiber laser welding of ferritic steel sheets of 30 mm thickness. Int J Adv Manuf Tech 88:1821–1830. https://doi.org/10.1007/s00170-016-8929-1
- 3.
Kusuda H, Takasago T, Natsumi F (1997) Formability of tailored blanks. J Mater Process Tech 71:134–140. https://doi.org/10.1016/S0924-0136(97)00159-3
- 4.
Ahmetoglu MA et al (1995) Deep drawing of round cups from tailor-welded blanks. J Mater Process Tech 53:684–694. https://doi.org/10.1016/0924-0136(94)01767-U
- 5.
Nothdurft S et al (2016) Laser soldering and brazing of steel-aluminum sheets for tailored hybrid tubes. J Laser Appl 28:022429. https://doi.org/10.2351/1.4943996
- 6.
Lange K (1988) Umformtechnik band 2: Massivumformung. Springer-Verlag, Berlin u. a
- 7.
Behrens BA et al (2016) Investigating the effects of cross wedge rolling preforming operation and die forging with flash brakes on forging titanium hip implants. Int J Mater Form. https://doi.org/10.1007/s12289-016-1329-0
- 8.
Wang M et al (2004) Hot deformation of austenite and prediction of microstructure evolution of cross-wedge rolling. Mater Sci Eng A 379:133–140
- 9.
Yuan WS, Wang L,Yuan TX (2015) Experimental study on cross wedge rolling process of aluminium alloy material. AEMT 415–422
- 10.
Ji H et al (2015) Cross-wedge rolling of a 4Cr9Si2 hollow valve - explorative experiment and finite element simulation. Int J Manuf Technol 77:15–26
- 11.
Pater Z, Tofil A, Tomczak T (2013) Steel balls forming by cross rolling with upsetting. METABK 52(1):103–106
- 12.
Pater Z, Gontarz W, Weronski W (2008) Cross rolling of parts with non-circular cross section. Arch Civil Mech Eng 8(2)
- 13.
Knust J, Stonis M, Behrens BA (2016) Perform optimization for hot forging processes using an adaptive amount of flash based on the cross section shape complexity. Prod Eng Res Devel. https://doi.org/10.1007/s11740-016-0702-7
- 14.
Knust J et al (2016) Preform optimization for hot forging processes using genetic algorithms. Int J Adv Manuf Technol, Springer London 85. https://doi.org/10.1007/s00170-016-9209-9
- 15.
Behrens BA et al (2013) Basic study on the process combination of deposition welding and subsequent hot bulk forming. Prod Eng Res Devel 7:585–591. https://doi.org/10.1007/s11740-013-0478-y
- 16.
Peng WF et al (2016) Stress distributions during the cross wedge rolling of composite 42CrMo/Q235 laminated shafts. Int J Adv Manuf Technol 83:145–155
- 17.
Blohm T et al (2017) Investigation of the coating thickness of plasma-transferred arc deposition welded and cross wedge rolled hybrid parts. Prod Eng Res Devel. https://doi.org/10.1007/s11740-017-0734-7
- 18.
Mildebrath M et al (2017) Influence of cross wedge rolling on the coating quality of plasma-transferred arc deposition welded hybrid steel parts. Int J Emerg Technol Adv Eng. ISSN 2250-2459, ISO 9001:2008 Certified Journal 7(7): 1–7
- 19.
Kache H, Stonis M, Behrens BA (2012) Development of a warm cross wedge rolling process using FEA and downsized experimental trials. Prod Eng Res Devel 6:339–348. https://doi.org/10.1007/s11740-012-0379-5
Acknowledgements
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 A3 and B1. The authors would like to thank the German Research Foundation (DFG) for the financial and organisational support of this project. The authors declare that they have no conflict of interest.
Author information
Affiliations
Corresponding author
Ethics declarations
The authors declare that they have no conflict of interest.
Rights and permissions
About this article
Cite this article
Blohm, T., Nothdurft, S., Mildebrath, M. et al. Investigation of the joining zone of laser welded and cross wedge rolled hybrid parts. Int J Mater Form 11, 829–837 (2018). https://doi.org/10.1007/s12289-017-1393-0
Received:
Accepted:
Published:
Issue Date:
Keywords
- Process chain
- Laser welding
- Hybrid parts
- Dissimilar joints
- Cross wedge rolling