Microstructural Evolution and Mechanical Properties of Hybrid Bevel Gears Manufactured by Tailored Forming
Abstract
:1. Introduction
2. State of the Art
3. Materials and Methods
3.1. Initial Geometry
3.2. Die Forging
3.3. Heat Treatment
3.4. Investigation of the Joining Zone
4. Results
5. Discussion
6. Conclusions
- The forming process has a great influence on the microstructure refinement. Due to the thermomechanical processing during forging, the initially coarse weld microstructure recrystallizes.
- The cooling strategy has the most important influence on the resulting values of hardness and tensile strength. High cooling rates by air-water spray quenching are the main strengthening factor. In air-cooled condition, hardness and strength remain almost unaffected.
- A process-integrated heat treatment by air-water spray quenching and self-tempering allows tailoring hardness and tensile strength in the cladding and the substrate.
- Since fracture of the hybrid tensile samples occurred in the lower strength substrate, a high quality of the bond at the interface was obtained.
- Hybrid bevel gears of the material combination 41Cr4/C22.8 manufactured by Tailored Forming feature a tensile strength similar to bevel gears of 41Cr4 mono-material.
- In comparison, bevel gears of the material combination X45CrSi9-3/C22.8 show a higher hardness in the cladding layer but a lower hardness in the substrate. While the increased hardness in the cladding is attributed to the formation of chromium carbides, the lower hardness in the substrate is caused by the increased self-tempering temperatures recommended for the steel grade X45CrSi9-3.
- The combination of Tailored Forming and a process-integrated heat treatment allows producing components with adapted hardness gradients by employing different materials and customized time-temperature profiles.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Material Combination | 41Cr4, 41Cr4/C22.8, Ø 27 and Ø 28 mm | X45CrSi9-3/C22.8, Ø 27 mm |
---|---|---|
Start temperature | 950 °C | 1000 °C |
Duration 1st phase | 10 s | 8 s |
Cooling medium 1st phase | Air-water spray | Air-water spray |
Tempering temperature 2nd phase | 300 °C | 750 °C |
Cooling medium 2nd phase | Air-water spray | Air-water spray |
Material Combination | 41Cr4/C22.8, Ø27 mm | 41Cr4/C22.8, Ø28 mm | X45CrSi9-3/C22.8, Ø27 mm | ||
---|---|---|---|---|---|
Cladded workpiece | Cladding layer | 299 ± 16 | 289 ± 13 | 379 ± 13 | |
Substrate | 164 ± 7 | 165 ± 13 | 146 ± 3 | ||
After forging | Position A | Cladding layer | 221 ± 9 | 262 ± 8 | 462 ± 77 |
Substrate | 170 ± 3 | 166 ± 4 | 148 ± 4 | ||
Position B | Cladding layer | 224 ± 7 | 238 ± 3 | 276 ± 4 | |
Substrate | 156 ± 8 | 152 ± 4 | 140 ± 2 | ||
After heat treatment | Position A | Cladding layer | 513 ± 7 | 539 ± 9 | 589 ± 23 |
Substrate | 410 ± 6 | 413 ± 6 | 268 ± 5 | ||
Position B | Cladding layer | 503 ± 6 | 534 ± 7 | 732 ± 7 | |
Substrate | 345 ± 12 | 340 ± 14 | 188 ± 3 |
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Behrens, B.-A.; Chugreeva, A.; Diefenbach, J.; Kahra, C.; Herbst, S.; Nürnberger, F.; Maier, H.J. Microstructural Evolution and Mechanical Properties of Hybrid Bevel Gears Manufactured by Tailored Forming. Metals 2020, 10, 1365. https://doi.org/10.3390/met10101365
Behrens B-A, Chugreeva A, Diefenbach J, Kahra C, Herbst S, Nürnberger F, Maier HJ. Microstructural Evolution and Mechanical Properties of Hybrid Bevel Gears Manufactured by Tailored Forming. Metals. 2020; 10(10):1365. https://doi.org/10.3390/met10101365
Chicago/Turabian StyleBehrens, Bernd-Arno, Anna Chugreeva, Julian Diefenbach, Christoph Kahra, Sebastian Herbst, Florian Nürnberger, and Hans Jürgen Maier. 2020. "Microstructural Evolution and Mechanical Properties of Hybrid Bevel Gears Manufactured by Tailored Forming" Metals 10, no. 10: 1365. https://doi.org/10.3390/met10101365