The idea of combining forming and joining technologies into hybrid forging was thought up by the engineers at the IPH, a research institute based in Hanover, Germany. Preliminary tests are promising: Tests with positive substance jointing and positive locking thru simultaneous forming of sheet metal and bulk parts have been successful. How the new technology can be put into practice is now the subject of a new research project conducted by the IPH. Until the end of the year technical requirements are going to be checked and tools are going to be developed.
“Hybrid forging can reduce process chains and thus reduce costs”, Hanns Kache, the engineer responsible for the project, explains. Thin elements of forgings might become lighter due to the use of sheet metal, without losing stability. Furthermore, highly stressed sheet metal parts might be enforced thru bulk elements. In the future, more combinations of both bulk and sheet metal parts will probably be used. “Hybrid forging is very attractive for the automobile industry, as the technology offers a lot of new possibilities with regard to both lightweight design and stability”, Kache forecasts. “Materials of any kind could be combined.”
Up till now bulk parts are produced through techniques such as forging. Sheet metal parts are being formed and partially, in an additional process, joined. To combine both the stability of bulk parts and the lightness of sheet metal parts, sheet metal elements can also be conjoined with bulk parts. An example of such a product are roof racks of convertibles. They are first formed and then joined. The hydro forging combines both steps. Thus, the production of goods like these becomes cheaper. Also, the construction of completely new parts becomes possible.
The one-year project ”hybrid forging“ started on 1 January 2011.
