Numerical Investigation of an Extruded Shaft for High Temperature Applications Manufactured by Tailored Forming

Components used in high temperature applications require special material properties to be able to withstand these external conditions. However, oftentimes only individual component areas are exposed to such requirements. Multi-material solutions facilitate the use of the right material at the right place, thus saving resources and costs. One approach, considered in the CRC “Tailored Forming”, is the use of pre-joined hybrid semi-finished products to manufacture high-performance multi material components. Within the scope of this study, the forming process for the production of a hybrid shaft made of the nickel-based alloys AISI alloy 625 and AISI 304 is numerically investigated. A material characterisation was carried out to analyse the different thermomechanical properties of the materials and to define a suitable process window in which the flow properties are adjusted. Furthermore, the influence of various die angles on the joining zone was investigated. A tool load analysis was finally carried out.