The german-based “Institut für Integrierte Produktion Hannover” (IPH) is working on the project together with two other research institutes and four enterprises from five European countries.
Forged preforms created by using cross wedge rolling must be further processed in order to obtain the final shape.
Cross wedge rolling in action at IPH: As part of the research project „CoVaForm“ a similar machine will be constructed and built, especially designed for titanium hip implants.
Whether producing engine parts, turbine blades or hip implants: Regarding forged parts, the material is the main component of the production costs, especially if a high duty material like titanium is used. During a new research project, IPH aims to develop a process in which less material is needed and which, at the same time, decreases time and energy consumption. This way, the researchers try to reduce the overall production costs significantly. Especially small and middle-sized forging enterprises will benefit from the results.
Die forging is forming of hot metal. To produce complex high duty parts, a single forging step is not enough to realize the complex shape. Therefore, so called preforms are produced during the forging process. To produce these preforms, different techniques are used. In most of the processes a lot of material gets lost: e. g. during machining a lot of excessive material is gradually removed – just like a sculptor removes excessive stone to expose the sculpture.
Cross wedge rolling (CWR) is the most efficient way to produce preforms. In this process the hot metal is formed into shape while rolling – just like a pottery maker is forming the figures by spinning the clay and forming it through gentle pressure.
The material utilization in cross wedge rolling is up to 100 percent. Also, less time and energy is needed, compared to machining. A lack of knowledge about the design of a cross wedge rolling process in general and especially for titanium and stainless steel is a main problem for the European forging industry. But particularly for these expensive materials an efficient material utilization has a great benefit.
To examine the cross wedge rolling technology, a titanium hip implant will be forged in the research project “CoVaForm”. The IPH has gained a lot of experience in cross wedge rolling during several research projects and will now build up a new CWR machine to produce preforms for a hip implant. This CWR machine will be tested at a collaboration partner by the middle of next year.
Funded by the EU, “CoVaForm” started January 1st 2014 and will last for a period of two years. The shortcut stands for “Conservation of valuable materials by a highly efficient forming system”. The project consortium consists of four enterprises and three research institutes from Germany, Spain, Italy, Austria and Turkey. This project is financially supported by the European Union as part of the seventh framework program (RP7).
The main interest lays in the help of small and middle-sized European forging plants to remain competitive in the international market and therefore help to secure approximately 68000 jobs – the number of people working in European forging plants in 2011. The overall sale in the sector was 12 billion Euros.
Companies who use forged parts for production will benefit in the long run due to more efficient forging processes and lower costs – first of all in the automotive industry, but also in the medical- and aerospace industries.
Evaluating risk of hydrogen embrittlement: new simulation of cold cracks in high-strength steels
03.05.2018 | Fraunhofer-Institut für Werkstoffmechanik IWM
Nanostructured Alloying with Oxygen
09.04.2018 | Max-Planck-Institut für Eisenforschung GmbH
At the LASYS 2018, from June 5th to 7th, the Laser Zentrum Hannover e.V. (LZH) will be showcasing processes for the laser material processing of tomorrow in hall 4 at stand 4E75. With blown bomb shells the LZH will present first results of a research project on civil security.
At this year's LASYS, the LZH will exhibit light-based processes such as cutting, welding, ablation and structuring as well as additive manufacturing for...
There are videos on the internet that can make one marvel at technology. For example, a smartphone is casually bent around the arm or a thin-film display is rolled in all directions and with almost every diameter. From the user's point of view, this looks fantastic. From a professional point of view, however, the question arises: Is that already possible?
At Display Week 2018, scientists from the Fraunhofer Institute for Applied Polymer Research IAP will be demonstrating today’s technological possibilities and...
So-called quantum many-body scars allow quantum systems to stay out of equilibrium much longer, explaining experiment | Study published in Nature Physics
Recently, researchers from Harvard and MIT succeeded in trapping a record 53 atoms and individually controlling their quantum state, realizing what is called a...
The historic first detection of gravitational waves from colliding black holes far outside our galaxy opened a new window to understanding the universe. A...
A team led by Austrian experimental physicist Rainer Blatt has succeeded in characterizing the quantum entanglement of two spatially separated atoms by observing their light emission. This fundamental demonstration could lead to the development of highly sensitive optical gradiometers for the precise measurement of the gravitational field or the earth's magnetic field.
The age of quantum technology has long been heralded. Decades of research into the quantum world have led to the development of methods that make it possible...
02.05.2018 | Event News
13.04.2018 | Event News
12.04.2018 | Event News
23.05.2018 | Life Sciences
23.05.2018 | Life Sciences
23.05.2018 | Physics and Astronomy