Forging of hybrid gears with wear-resistant surfaces using deposition-welded semi-finished products
Niklas GERKE, Laura BUDDE, Eduard ORTLIEB, Simon PEDDINGHAUS, Kai BIESTER, Julius PEDDINGHAUS, Hendrik WESTER, Johanna UHE, Jörg HERMSDORF, Nick SCHWARZ, Ludger OVERMEYER, Bernd-Arno BEHRENS
Abstract. New technologies are needed to keep up with the increasing demand for high-performance components. One approach is to forge hybrid components from prefabricated multimaterial billets (Tailored Forming). This work focuses on the material distribution after a die forging process investigating the example of a hybrid spur gear. Different layer thicknesses of the material X45CrSi9-3 were applied to a blank made of C22.8 using a laser hot-wire cladding process. The semi-finished products were then hot-formed into near-net-shape spur gears. In order to investigate the influence of different cladding thicknesses on the material distribution across the tooth geometry after hot forging, metallographic sections were analyzed. The joining zone microstructure was analyzed for defects and hardness measurements were carried out. In addition, FEM was used to simulate how different layer thicknesses of a cladded blank affect the material distribution in forming. The results of the numerical and experimental analysis showed that the resulting material distribution can be predicted with high precision using FE process modeling.
Keywords
Die forging, Laser Hot-Wire Cladding, Hybrid Components, Tailored Forming, Directed Energy Deposition
Published online 5/7/2025, 10 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Niklas GERKE, Laura BUDDE, Eduard ORTLIEB, Simon PEDDINGHAUS, Kai BIESTER, Julius PEDDINGHAUS, Hendrik WESTER, Johanna UHE, Jörg HERMSDORF, Nick SCHWARZ, Ludger OVERMEYER, Bernd-Arno BEHRENS, Forging of hybrid gears with wear-resistant surfaces using deposition-welded semi-finished products, Materials Research Proceedings, Vol. 54, pp 936-945, 2025
DOI: https://doi.org/10.21741/9781644903599-100
The article was published as article 100 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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