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8. September 2015

Residual stress makes hybrids more durable

IFW | Where steel is too heavy and aluminium too soft, the future is a combination of both materials. The lifespan of hybrids depends on the residual stresses induced by the final machining process. The goal of IFW scientists is to control these residual stresses.

Planing, turning, milling: After forming, nearly every component needs to be machined, affecting properties, such as wear resistance and lifetime. The machining process can induce residual stresses in the component, with the result that for example minor cracks close on their own and make the component more durable.
Within the scope of the Collaborative Research Centre (CRC) 1153, the Institute of Production Engineering and Machine Tools (IFW) is focusing on the formation and modification of such residual stresses. The aim is to improve the properties of a hybrid’s individual materials and to investigate the residual stresses in the area of material transition between the two different materials. The residual stresses shall then be influenced in a controlled manner to increase the bond quality between steel and aluminium.

by Rolf Hockauf

At a glance

  • CRC 1153, Subproject B4: Function-oriented process planning
  • Funded by the German Research Foundation (DFG)
  • Increased fatigue strength of hybrid components by controlled residual stresses
IFW_SFB1153-B4_Bild1_03
Figure 1: Turning induces residual stresses in components – for example in magnesium screws for use in medical applications. (Photo: Patrick Helmecke)
IFW_SFB1153-B4_Bild2_03
Figure 2: Turning tool affecting the area of material transition of the hybrid material compound (Graphic: Rolf Hockauf)
IFW_SFB1153-B4_Bild3_eng
Figure 3: Preliminary tests in the area of material transition of a friction-welded compound made of two steels (Graphic: Rolf Hockauf)
IFW_SFB1153-B4_Bild4_eng
Figure 4: Schematic diagram of component development steps today and in future (Graphic: Rolf Hockauf)
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Rolf Hockauf

+49 (0) 511 762 4788

Hockauf@ifw.uni-hannover.de

www.ifw.uni-hannover.de

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