Production of complex geometries made of particle reinforced steel materials by powder compaction and subsequent thixoforging

• Applicant: Professor Dr.-Ing. Bernd-Arno Behrens
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: from 2010 to 2019
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 147785650

Within the first project phase the provided process chain for the production of model components made of particle reinforced steel materials could be realized by powder pressing with subsequent thixoforging. For this purpose, cylindrical semi-finished products with and without reinforcement particles (titanium carbide powder) were produced by powder metallurgical processes. The specific material factors for pressing and sintering depending on the reinforcement phase were identified. By means of the inductive heating process the semi-finished products were heated up to the thixotropic temperature range, whereby a sufficient dimensional stability of parts could be detected. The thixoforging process also has shown that a complete filling of the mold for the selected geometry could be achieved by the determined of the forging parameters. In addition, the produced compo-nents were characterized by micrographs, hardness measurements and tensile tests.Based on the described results in the second project phase the complexity of the thixoforged com-ponents should be significantly increased. Using the results of the production and heating of the semi-finished products two very complex component geometries should be manufactured by thixoforging of particle reinforced steel materials. In addition, the specific advantages of powder metallurgy should be used for the production of semi-finished products with partial particle reinforcement. This way, complex components with adapted material properties can be manufactured, which can better resist an existing stress profile in use. An important aim of the provided process chain is to adapt the inductive heating process as well as the forming process on the partially particle reinforced semi-finished products.

• DFG Programme: Research Grants