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Coating as wear protection for hot forming tools

(Kopie 3)

Project Leader:<strong/> Dr. K. Möhwald (Dr.Eng. habil.), Prof. B.-A. Behrens (DR.Eng)

Funding period: until 08/2015
Funding body:<strong/> DFG
Funding reference: -

Drop forgings made from steel are currently used in many fields due to their exceptional mechanical properties. The tool life of a forging tool is one of the decisive factors for economic production. In addition to this, growing competitive pressure compels companies to manufacture products with increasingly high quality at ever falling prices. Depending on the procedure used, tools use in hot forging are subject to high thermal, mechanical and tribological loads. These loads generally overlap and result in the failure of the tools used for various causes. Accounting for 70% of cases, wear is the main cause of tool failure. The increase in the wear resistance of the forming tool surface is therefore of vital significance with regard to increasing tool life and improving profitability. Alongside thermal and thermo-chemical surface treatment procedures, coating procedures for the application of thin, wear-resistant layers are also increasing in significance in this regard.

The objective of this research project is the application of wear-reducing coatings from collaborative research centre 489 (CRC 489) run by the German Research Community (Deutsche Forschungsgemeinschaft, DFG), Sub-project AI "Materials for precision forging" to various hot forming processes. One challenge here is the transfer of previous experiences and process- and tool-appropriate adjustments to the requirements of various forging processes and tool systems. Following the selection of layer systems adjusted to suit the process conditions, a preliminary study of the wear behaviour takes place using model tools. Subsequently, the layer systems with the lowest wear are transferred to industrial processes. In addition to different tools, various types of forging presses are also used here. In addition to the eccentric presses previously considered in CRC 489, layer systems are also being trialled with a view to reducing wear on fast-moving Hatebur presses. The use of coatings on this type of press presents a particular challenge on account of the high die speeds and temperature fluctuation e.g. with regard to adhesion to the surface. Finally, in addition to the reduction of tool wear, the costs of the coating process will be optimised, thus enabling a further increase in economy.


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