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19. September 2016

UHC steel: New material for lightweight construction

IFUM/IFW | High-strength, lightweight steel at low price: UHC steel could replace conventional steel and reduce the weight of motor components like piston pins. Scientists and industrial companies are jointly working on a process chain for the novel lightweight material.

Aluminium alloy lightweight structural steels, also called ultra-high carbon (UHC) steels, have a ten percent lower density than today’s high-performance steels. Consequently, they have a lighter weight – at comparable strength. The drawback: Machining of UHC steels is not so easy.
Within the scope of the project "IPROM", researchers at the Institute of Forming Technology and Machines (IFUM) carried out a complete material characterization of the lightweight structural steel, in order to examine its behaviour during the forming process. The result: Higher forces are needed to form the novel material. Due to the low thermal conductivity, high temperatures are developed in the tool during the machining process. Moreover, UHC steel is quite brittle.
Forming and machining of UHC steel is difficult when using conventional tools and manufacturing processes. In cooperation with IFW and project partners from industry, IFUM has therefore simulated and developed a completely new process route – using the example of the production of piston pins (see Figure 4).

by Delil Yarcu and Mohammad Kazhai

Significance for the production

  • Newly developed aluminium alloyed UHC steel
  • Material characterization and FE simulation
  • Integration of the novel material into the process chain
  • Shortening oft the process chain through precision forging
IFUM_Leichtbaustahl_Bild1_01
This piston pin made of ultra-high carbon steel is light, but still has a high strength. (Source: IFUM)
IFUM_Leichtbaustahl_Bild2_EN
Research institutes and industrial companies jointly develop manufacturing methods for UHC steels. (Source: IFUM)
IFUM_Leichtbaustahl_Bild3_EN
The process-independent material model shows the behaviour of the novel lightweight structural steel during the forming process. (Source: IFUM)
IFUM_Leichtbaustahl_Bild4_EN
Process steps for the production of piston pins and simulation of the tool system. (Source: IFUM)
IFUM_Leichtbaustahl_Bild5_EN
The project “IPROM“ stands for “Innovative Process Chain for the Production of Massive Parts Made of Novel Lightweight Structural Steel“. (Source: IFUM)
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Dipl.-Ing. Delil Yarcu

+49 (0)511 – 762-2166

yarcu@ifum.uni-hannover.de

www.ifum.uni-hannover.de

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