Patterning of Surfaces for Subsequent Roll Bonding in a Low-Oxygen Environment Using Deformable Mesh Inlays

Efficient roll bonding for the manufacturing of clad strips not only requires surface activation but also is improved by a surface patterning to reduce the initial contact area. This increases contact stresses and facilitates a joining without an increasing rolling force. Experiments to pattern surfaces with deformable inlays during cold rolling for a subsequent bonding in low-oxygen atmosphere were carried out using two types of rolling mills, two types of inlays and two types of assemblies. Digital twins of selected experiments were created by means of the FE simulation software QForm UK 10.2.4. The main set of rolling parameters, which play a significant role during formation of the pattern shape considering deformation of the patterning tool, were investigated. The pilot roll bonding of patterned components under vacuum conditions, provided using vacuum sealer bags, allowed for an experimental realization of this approach. The concept technological chain of roll bonding in a low-oxygen or oxygen-free environment comprises the following stages: roll patterning; surface activation and sealing of the strips in a vacuum bag; subsequent roll bonding of the prepared strips inside the protective bag. The difference between the shape of the pattern created and the initial shape of the mesh insert can be quantitatively described by the change of its angle. This difference reaches maximum values when smaller rolls are used with increased rolling reductions. This maximum value is limited by the springback of the deformed insert; the limit is reached more easily if the inlay is not positioned on the rolling plane

Investigations of ductile damage in DP600 and DC04 deep drawing steel sheets during punching

The paper presents numerical and microstructural investigations on a punching process of 2 mm thick steel sheets. The dual phase steel DP600 and the mild steel DC04 exhibit different damage and fracture characteristics. To distinguish the void development and crack initiation for both materials, interrupted tests at varied punch displacements are analyzed. The void volume fractions in the shearing zone are identified by scanning electron microscopy (SEM). The Gurson model family, which is recently extended for shear fracture, is utilized to model the elastoplastic behavior with ductile damage. The effect of the shear governing void growth parameter, introduced by Nahshon and Hutchinson (2008), is discussed

Investigations on Additively Manufactured Stainless Bearings

Additive manufacturing with multi-material design offers great possibilities for lightweight and function-integrated components. A process chain was developed in which hybrid steel–steel-components with high fatigue strength were produced. For this, a material combination of stainless powder material Rockit® (0.52 wt.% C, 0.9% Si, 14% Cr, 0.4% Mo, 1.8% Ni, 1.2% V, bal. Fe) cladded onto ASTM A572 mild steel by plasma arc powder deposition welding was investigated. Extensive material characterization has shown that defect-free claddings can be produced by carefully adjusting the welding process. With a tailored heat treatment strategy and machining of the semi-finished products, bearing washers for a thrust cylindrical roller bearing were produced. These washers showed a longer fatigue life than previously produced bearing washers with AISI 52100 bearing steel as cladding. It was also remarkable that the service life with the Rockit® cladding material was longer than that of conventional monolithic AISI 52100 washers. This was reached through a favourable microstructure with finely distributed vanadium and chromium carbides in a martensitic matrix as well as the presence of compressive residual stresses, which are largely retained even after testing. The potential for further enhancement of the cladding performance through Tailored Forming was investigated in compression and forging tests and was found to be limited due to low forming capacity of the material

Make EU trade with Brazil sustainable

Brazil, home to one of the planet's last great forests, is currently in trade negotiations with its second largest trading partner, the European Union (EU). We urge the EU to seize this critical opportunity to ensure that Brazil protects human rights and the environment