Numerical process design for the production of a hybrid die made of tool steel X38CrMoV5.3 and inconel 718

Abstract

Abstract. Dies used in hot forging are subjected to high cyclic thermo-mechanical loads, which lead to die failure. There are various options for increasing the service life of these dies, for example coatings or heat treatments. Another possibility is to adapt the choice of material, which is the focus of this work. For example, the nickel-based alloy Inconel has a higher strength at elevated temperatures compared to tool steel. However, Inconel is difficult to manufacture and has higher material costs. For this reason, a new process design for the production of a hybrid die consisting of Inconel 718 and tool steel X38CrMoV5.3 is presented within this work. To produce the hybrid dies, the two materials are first friction welded and then formed using hot forging. In addition to the numerical process design, experimental tests are also carried out to manufacture such hybrid dies. Furthermore, a numerical parameter study is done to determine the influence of the forging temperature, the forging speed and the initial Inconel thickness on the process parameters. It can be shown that the production of hybrid dies is possible by using the Tailored Forming process chain. The influencing factors investigated change the required press force and also the material distribution of the Inconel in the hybrid die produced. In the future, further experimental tests will be carried out to determine the service life of the hybrid dies.