Forging of Lightweight Hybrid Metallic-Plastic Components

With the focus of lightweight constructions, the process line from producing of semi-finished products up to the second processing step of forging was investigated for composite of plastic (PA6) and aluminium alloy (EN-AW6060). Especially the material or deformation behaviour were determined fundamentally. For analysing the temperature-dependent material flow, the three basic kinds of forging (upsetting, rising and spreading) were considered under laboratory conditions by using an oil-hydraulic forging press. The results show that the temperature profile over the cross-section of the composite and the ratio between aluminium and plastic is sensitive for the process stability and the forging of faultless components. Due to the decomposition temperature of the plastic, a gradient temperature is necessary for the forging of hybrid plastic-metal composites. It must also be regarded that the diameter-height-ratio is important to eliminate the risk of buckling during upsetting. Additionally, the physical simulation takes into account for the identification of the process window for forging. The potential for weight reduction of the plastic-metal-hybrid is approximately 30% higher in comparison to a monolithic aluminium component.