Institute of Transport and Automation Technology Research Publications
Forging of hybrid gears with wear-resistant surfaces using deposition-welded semi-finished products

Forging of hybrid gears with wear-resistant surfaces using deposition-welded semi-finished products

Categories Zeitschriften/Aufsätze (reviewed)
Year 2025
Authors Gerke, N.; Budde, L.; Ortlieb, E.; Peddinghaus, S.; Biester, K.; Peddinghaus, J.; Wester, H.; Uhe, J.; Hermsdorf, J.; Schwarz, N. Overmeyer, L.; Behrens, B.-A.
Published in Material Forming
Description

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.