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Open AccessArticle

Numerical Simulation and Experimental Validation of the Cladding Material Distribution of Hybrid Semi-Finished Products Produced by Deposition Welding and Cross-Wedge Rolling

1
Institut für Integrierte Produktion Hannover gGmbH, Hollerithallee 6, 30419 Hannover, Germany
2
Leibniz Universität Hannover, Institute of Materials Science, An der Universität 2, 30823 Garbsen, Germany
3
Laser Zentrum Hannover e.V., Hollerithallee 8, 30419 Hannover, Germany
4
Leibniz University Hannover, Institute of Machine Design and Tribology, An der Universität 1, 30823 Garbsen, Germany
*
Author to whom correspondence should be addressed.
Metals 2020, 10(10), 1336; https://doi.org/10.3390/met10101336
Received: 25 August 2020 / Revised: 29 September 2020 / Accepted: 2 October 2020 / Published: 6 October 2020
(This article belongs to the Special Issue Hybrid Bulk Metal Components)
The service life of rolling contacts is dependent on many factors. The choice of materials in particular has a major influence on when, for example, a ball bearing may fail. Within an exemplary process chain for the production of hybrid high-performance components through tailored forming, hybrid solid components made of at least two different steel alloys are investigated. The aim is to create parts that have improved properties compared to monolithic parts of the same geometry. In order to achieve this, several materials are joined prior to a forming operation. In this work, hybrid shafts created by either plasma (PTA) or laser metal deposition (LMD-W) welding are formed via cross-wedge rolling (CWR) to investigate the resulting thickness of the material deposited in the area of the bearing seat. Additionally, finite element analysis (FEA) simulations of the CWR process are compared with experimental CWR results to validate the coating thickness estimation done via simulation. This allows for more accurate predictions of the cladding material geometry after CWR, and the desired welding seam geometry can be selected by calculating the cladding thickness via CWR simulation. View Full-Text
Keywords: tailored forming; cross-wedge rolling; welding; PTA; LMD-W; forming; rolling; coating tailored forming; cross-wedge rolling; welding; PTA; LMD-W; forming; rolling; coating
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Kruse, J.; Mildebrath, M.; Budde, L.; Coors, T.; Faqiri, M.Y.; Barroi, A.; Stonis, M.; Hassel, T.; Pape, F.; Lammers, M.; Hermsdorf, J.; Kaierle, S.; Overmeyer, L.; Poll, G. Numerical Simulation and Experimental Validation of the Cladding Material Distribution of Hybrid Semi-Finished Products Produced by Deposition Welding and Cross-Wedge Rolling. Metals 2020, 10, 1336.

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