SFB 692: High-strength Aluminium-Based Light Weight Materials for Reliable Components
Mechanical and Industrial Engineering
Social and Behavioural Sciences
Final Report Abstract
The main objective of CRC 692 was to investigate and exploit the potential of aluminum-based lightweight materials, taking into account the different influences along the process chain during manufacturing of safety components. The research focused on the development, production and characterization as well as on the use of new lightweight materials in safety-related applications. One challenge was that material concepts and manufacturing processes had to be coordinated in such a way that high reliability requirements could be met throughout the entire product life cycle. Especially mass and cost reduction also played an important role in the CRC. Forming techniques represent a successful and highly efficient approach for producing excellent mechanical properties, such as high strength combined with good ductility. The research work in the CRC – which can be structured along the three main development lines "High-strength wrought Al alloys", "Aluminum Matrix Composites (AMCs)" and "High-strength Al-based composites" – therefore aimed at designing, manufacturing and refining aluminum-based lightweight materials in the light of high quality requirements. Research in the first development line was focused on the production of fine and ultrafine-grained (UFG) microstructures in high-strength Al alloys, which exhibit previously unattainable strength-ductility combinations and, in part, a significantly improved corrosion behavior. Grain refinement was achieved by Severe Plastic Deformation (SPD) processes, in particular by Equal Channel Angular Pressing (ECAP) and closely related processing techniques. In addition to the formation of UFG microstructures, these techniques were used to investigate the precipitation kinetics of age-hardening Al alloys. Optimized heat treatments could be developed, which allow an economic adjustment of the desired property combinations. In addition, extensive micro- and continuum-mechanical modeling allowed the elementary processes that occur in complex deformation paths to be studied in detail. Further investigations were carried out to investigate how UFG surfaces can be produced without cracking in graded semi-finished products (with conventional grain sizes in the core) and how microstructural gradients affect the properties of the semi-finished products. Additional research activities considered the novel approach to develop an SPD process for shaped parts, investigated how low temperatures affect the maximum achievable forming degrees, and analyzed within which process limits deformation localizations can be avoided in SPD processes. The second development line focused on particle-reinforced aluminum matrix composites (AMCs) as well as the machining or electrochemical micro-structuring of their surfaces. By high-energy ball milling, composite powders and compact semi-finished products were produced utilizing nano-scale hard particles and the gas pressure infiltration process. The AMCs have a high potential, e.g., for applications where elevated temperatures and / or tribological loads occur. Therefore, especially in the third funding period, in addition to new consolidation procedures and the creation of tailor-made matrices by varying the alloying elements, the thermal stability of the AMCs at elevated temperatures was carefully investigated. The third development line was initially limited to the investigation of aluminum-coated magnesium composites, which combine additional mass reduction with good corrosion protection. For a successful implementation of this concept, microstructural and micromechanical processes at internal interfaces and outer surfaces were examined in detail. In the third funding period, additional focus was placed on composites with steel materials, which significantly expanded the potential range of applications for high-strength aluminum-based materials. The joint research and collaboration of the scientific subprojects in five working groups allowed to systematically consider topics of general importance such as low temperature forming, thermal stability and joining with other material classes, which are of particular relevance for the application of high strength Al-based materials in industrial practice. In the second and third funding period, a total of seven transfer projects were successfully initiated, where, together with industry partners, the fundamental knowledge of the engineering science-focused CRC was transformed towards industrial application.
Publications
- Sheet Metal Forming at Elevated Temperatures. Annals of the CIRP 55, 2006, 793-816
Neugebauer, R., Altan, T., Geiger, M., Kleiner, M., Sterzing, A.
(See online at https://doi.org/10.1016/j.cirp.2006.10.008) - Compressive behaviour of ultrafine-grained AA6063T6 over a wide range of strains and strain rates. International Journal of Materials Research 98, 2007,191-199
Meyer, L.W., Hockauf, M., Krüger, L., Schneider, I.
(See online at https://doi.org/10.3139/146.101462) - Effects of pre-treatment on the growth rate and morphology of hard anodic films on aluminium (EN AW-6082). Surface and Coatings Technology 202, 2007, 569-576
Wielage, B., Nickel, D., Alisch, G., Podlesak, H., Lampke, T.
(See online at https://doi.org/10.1016/j.surfcoat.2007.06.052) - Application of a coordinate-free tensor formalism to the numerical implementation of a material model. Journal of Applied Mathematics and Mechanics (ZAMM) 88, 2008, 888-909
Shutov, A.V., Kreißig, R.
(See online at https://doi.org/10.1002/zamm.200800017) - Crack growth in ultrafine-grained AA6063 produced by equal-channel angular pressing. Journal of Materials Science 43, 2008, 7426-7431
Meyer, L.W., Sommer, K., Halle, T., Hockauf, M.
(See online at https://doi.org/10.1007/s10853-008-2725-8) - Finite strain viscoplasticity with nonlinear kinematic hardening: phenomenological modelling and time integration. Computer Methods in Applied Mechanics and Engineering 197, 2008, 2015-2029
Shutov, A.V., Kreißig, R.
(See online at https://doi.org/10.1016/j.cma.2007.12.017) - Mechanical properties and corrosion behaviour of ultrafine-grained AA6082 produced by equal-channel angular pressing. Journal of Materials Science 43, 2008, 7409-7417
Hockauf, M., Meyer, L.W., Nickel, D., Alisch, G., Lampke, T., Wielage, B., Krüger, L.
(See online at https://doi.org/10.1007/s10853-008-2724-9) - Nanocrystalline Al-Al2O3p and SiCp composites produced by high-energy ball milling. Journal of Materials Processing Technology 205, 2008, 111-118
Oezdemir, I., Ahrens, S., Mücklich, S., Wielage, B.
(See online at https://doi.org/10.1016/j.jmatprotec.2007.11.085) - Investigation of Mechanical and Microstructural Characteristics of Al-Mg Compounds. Advanced Engineering Materials 11, 2009, 568-572
Neugebauer, R., Glaß, R., Popp, M., Lampke, T., Alisch, G., Nickel, D.
(See online at https://doi.org/10.1002/adem.200900069) - Simultaneous improvement of strength and ductility of Al-Mg-Si alloys by combining equal-channel angular extrusion with subsequent high-temperature short-time aging. Materials Science and Engineering A 503, 2009, 167-171
Hockauf, M., Meyer, L.W., Zillmann, B., Hietschold, M., Schulze, S., Krüger, L.
(See online at https://doi.org/10.1016/j.msea.2008.02.051) - Characterization of contact tensions during incremental forming of metal composites. International Journal of Material Forming 3, 2010, 667-670
Neugebauer, R., Meinel, S., Glass, R., Popp, M.
(See online at https://doi.org/10.1007/s12289-010-0858-1) - Regularized strategies for material parameter identification in the context of finite strain plasticity. Technische Mechanik 30, 2010, 280-295
Shutov, A.V., Kreißig, R.
- Verfahren zur Erhöhung von Festigkeit und Verformbarkeit von ausscheidungshärtbaren Werkstoffen (DE102008033027B4)
Hockauf, M., Meyer, L.W., Krüger, L.
- Verfahren zur Veränderung der Korngröße in einem massiven, zylindrischen Werkstück und Werkstück (DE102009033647B3)
Bergmann, M., Popp, M.
- Controlled grain size distribution and refinement of an EN AW-6082 aluminium alloy. International Journal of Materials Research 102, 2011, 977-981
Lampke, T., Dietrich, D., Nickel, D., Bergmann, M., Zachäus, R., Neugebauer, R.
(See online at https://doi.org/10.3139/146.110546) - Microstructural Features and Mechanical Properties after Industrial Scale ECAP of an Al-6060 alloy. Materials Science Forum 667-669, 2011, 1153-1158
Frint, P., Hockauf, M., Halle, T., Strehl, G., Lampke, T., Wagner, M.F.-X.
(See online at https://doi.org/10.4028/www.scientific.net/MSF.667-669.1153) - Property distribution in aluminium material processed by gradation rolling. Steel Research International (Special Edition: 10th International Conference on Technology of Plasticity, Aachen), 2011, 127-130
Neugebauer, r., Sterzing, A., Zachäus, R., Bergmann, M.
- Residual Stress Analysis of Al/Mg Compounds by Using the Hole Drilling Method. Journal of JSEM 11, 2011, 233-238
Lehmann, T., Stockmann, M.
- A viscoplasticity model with an enhanced control of the yield surface distortion. International Journal of Plasticity 39, 2012, 152-167
Shutov, A.V., Ihlemann, J.
(See online at https://doi.org/10.1016/j.ijplas.2012.06.006) - Cryogenic forming of AA7075 by Equal-Channel Angular Pressing. Materialwissenschaft und Werkstofftechnik 43, 2012, 561-566
Fritsch, S., Scholze, M., Wagner, M.F.-X.
(See online at https://doi.org/10.1002/mawe.201200001) - Electrochemical properties of Al-6060 alloy after industrial scale ECAP. Materials Science 48, 2012, 191-196
Yulinova, A., Nickel, D., Frint, P., Lampke, T.
(See online at https://doi.org/10.1007/s11003-012-9490-1) - High-strength aluminum-based light-weight materials for safety components – recent progress by microstructural refinement and particle reinforcement. International Journal of Materials Research 103, 2012, 3-11
Hockauf, M., Wagner, M.F.-X., Händel, M., Lampke, T., Siebeck, S., Wielage, B.
(See online at https://doi.org/10.3139/146.110631) - Microstructure, crystallographic texture and mechanical properties of the magnesium alloy AZ31B after different routes of thermo-mechanical processing. International Journal of Plasticity 35 , 2012, 155-166
Seipp, S., Wagner, M.F.-X., Hockauf, M., Schneider, I., Meyer, L.W., Hockauf, M.
(See online at https://doi.org/10.1016/j.ijplas.2012.03.007) - The role of Backpressure during large scale Equal-Channel Angular Pressing. Materialwissenschaft und Werkstofftechnik 43, 2012, 668- 672
Frint, P., Hockauf, M., Halle, T., Wagner, M.F.-X., Lampke, T.
(See online at https://doi.org/10.1002/mawe.201200015) - Verfahren und Vorrichtung zur Herstellung eines querfließgepressten Verbundkörpers und querfließgepresster Verbundkörper (DE102009032435B4)
Popp, M.
- Verfahren und Vorrichtung zur Korngrößenbeeinflussung eines Werkstückes sowie Werkstück (DE102012006952B4)
Zachäus, R., Bergmann, M.
- Verfahren zur Finishbearbeitung von Oberflächen und Rollwerkzeug hierfür (DE102011116886A1)
Richter, D., Schmidt, T., Schneider, J., Schubert, A.
- Influence of precipitates on low-cycle-fatigue and crack growth behavior in an ultrafine-grained aluminum alloy. Acta Materialia 80, 2014, 250-263
Hockauf, K., Wagner, M.F.-X., Halle, T., Niendorf, T., Hockauf, M., Lampke, T.
(See online at https://doi.org/10.1016/j.actamat.2014.07.061) - On a dislocation density based two-phase plasticity model: refinement and extension to non-proportional loading. International Journal of Plasticity 55, 2014, 58–79
Silbermann, C. B., Shutov, A.V., Ihlemann, J.
(See online at https://doi.org/10.1016/j.ijplas.2013.09.007) - Effect of Strain Localization on Pitting Corrosion of an AlMgSi0.5 Alloy. Metals 5, 2015, 172-191
Nickel, D., Dietrich, D., Mehner, T., Frint, P., Spieler, D., Lampke, T.
(See online at https://doi.org/10.3390/met5010172) - Extending the scope of Material Flow Cost Accounting – methodical refinements and use case, in: Journal of Cleaner Production 108, 2015, 1320-1332
Schmidt, A., Götze, U., Sygulla, R.
(See online at https://doi.org/10.1016/j.jclepro.2014.10.039) - Formation of grains and dislocation structure of geometrically necessary boundaries. Materials Science and Engineering A 643, 2015, 12-16
Koster, M., Le, Khanh C.
(See online at https://doi.org/10.1016/j.msea.2015.07.027) - Influencing the gradient of material properties by gradation extrusion, Applied Mechanics and Materials 794, 2015, 166-173
Landgrebe, D., Sterzing, A., Bergmann, M.
(See online at https://doi.org/10.4028/www.scientific.net/AMM.794.166) - Anodic oxidation of AlMgSi1 – Coatings´ mechanical properties, process costs and energy consumption of the oxide formation. Materials and Design 89, 2016, 1259–1269
Sieber, M., Scharf, I., Herold, F., Schmidt, A., Böttger, D., Böttger, S., Böttger, E., Götze, U., Lampke, T.
(See online at https://doi.org/10.1016/j.matdes.2015.10.064) - Influence of thermally activated processes on the deformation behavior during low temperature ECAP, IOP Conf. Ser.: Mater. Sci. Eng. 118 (012030), 2016
Fritsch, S., Scholze, M., Wagner, M.F.-X.
(See online at https://doi.org/10.1088/1757-899X/118/1/012030) - An experimental study on optimum lubrication for large-scale severe plastic deformation of aluminum-based alloys. Journal of Materials Processing Technology 239, 2017, 222-229
Frint, P., Wagner, M.F.-X., Weber, S., Seipp, S., Frint, S., Lampke, T.
(See online at https://doi.org/10.1016/j.jmatprotec.2016.08.032) - Effect of Creep and Aging on the Precipitation Kinetics of an Al-Cu Alloy after One Pass of ECAP, Advanced Engineering Materials 20 (1700307), 2017
Härtel, M., Frint, P., Abstoss, K.G., Wagner, M.F.-X.
(See online at https://doi.org/10.1002/adem.201700307) - Microstructure and mechanical properties of an AA6060 aluminum alloy after cold and warm extrusion. Materials Science and Engineering A 707, 2017, 717-724
Berndt, N., Frint, P., Böhme, M., Wagner, M.F.-X.
(See online at https://doi.org/10.1016/j.msea.2017.09.040) - Werkzeug mit geometrisch bestimmter Schneide zur spanabhebenden Finishbearbeitung einer Werkstückoberfläche, Werkzeugschneidengeometrie, Verfahren und Werkstück mit einer endbearbeiteten Funktionsoberfläche (DE102011116918B4)
Schubert, A., Schmidt, T., Schneider, J., Richter, D.
- Geometrically linear continuum theory of dislocations revisited from a thermodynamical perspective. Archive of Applied Mechanics Special 88, 2018, 141-173
Silbermann, C. B., Ihlemann, J.
(See online at https://doi.org/10.1007/s00419-017-1296-z) - Microstructural Evolution during Severe Plastic Deformation by Gradation Extrusion. Metals 8, 2018, 96
Frint, P., Härtel, M., Selbmann, R., Dietrich, D., Bergmann, M., Lampke, T., Landgrebe, D., Wagner, M.F.-X.
(See online at https://doi.org/10.3390/met8020096) - On the Effect of Natural Aging Prior Low Temperature ECAP of a High- Strength Aluminum Alloy. Metals 8, 2018, 63
Fritsch, S., Wagner, M.F.-X.
(See online at https://doi.org/10.3390/met8010063) - Process Chain for the Production of a Bimetal Component from Mg with a Complete Al Cladding. Metals 8, 2018, 97
Förster, W., Binotsch, C., Awiszus, B.
(See online at https://doi.org/10.3390/met8020097) - Roller Burnishing of Particle Reinforced Aluminum Matrix Composites. Metals 8, 2018, 95
Nestler, A., Schubert, A.
(See online at https://doi.org/10.3390/met8020095) - Strain Localization during Equal-Channel Angular Pressing Analyzed by Finite Element Simulations. Metals 8, 2018, 55
Horn, T.D., Silbermann, C.B., Frint, P., Wagner, M.F.-X., Ihlemann, J.
(See online at https://doi.org/10.3390/met8010055) - Temperature and Particle Size Influence on the High Cycle Fatigue Behavior of the SiC Reinforced 2124 Aluminum Alloy. Metals 8, 2018, 43
Winter, L., Hockauf, K., Lampke, T.
(See online at https://doi.org/10.3390/met8010043)
