The best of two materials: light and strong at the same time

In a joining experiment, a galvanized aluminium stud was joined to a galvanized steel sheet. (Photo: IPH)

IPH | Hybrid structures used in automotive lightweight design are composed of different materials as well as of bulk and sheet metal parts. Hybrid compound forging is a method to create a material bond between a steel sheet and a bulk aluminium part already during the forming process.

Lightweight construction plays an important role in automotive and aerospace industry. In cooperation with the Institute of Welding and Machining (ISAF) of TU Clausthal, the Institut für Integrierte Produktion Hannover (IPH) gGmbH is doing research on how to create a material bond between aluminium studs and steel sheets — combining material and structure lightweight design. Solid materials are used to withstand higher stresses, lightweight and less solid materials are employed in areas where lower stresses are expected.

The material bond between the two joining partners is created in a forming process. To determine the appropriate joining parameters, the researchers are investigating different temperature ranges (100 to 360 degree Celsius) and forming speeds (50 to 460 millimetres per second).

by Mareile Kriwall

Image gallery for this article

  • In a joining experiment, a galvanized aluminium stud was joined to a galvanized steel sheet. (Photo: IPH)
  • The micrograph of an aluminium stud formed at 350° C shows: The zinc coating is not entirely torn open but still intact, so that there is no immediate contact between aluminium and steel sheet. (Source: ISAF)
  • The forming tool’s structural design must allow for a large forming in the joining zone. (Source: IPH)
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