A novel co-extrusion process for the production of coaxially reinforced hollow profiles has been developed. Using this process, hybrid hollow profiles made of the aluminum alloy EN AW-6082 and the case-hardening steel 20MnCr5 (AISI 5120) were produced, which can be forged into hybrid bearing bushings by subsequent die forging. For the purpose of co-extrusion, a modular tooling concept was developed where steel tubes made of 20MnCr5 are fed laterally into the tool. This LACE (lateral angular co-extrusion) process allows for a variation of the volume fraction of the reinforcement by using steel tubes with different wall thicknesses, which enabled the production of compound profiles having reinforcement contents of either 14 vol.% or 34 vol.%. The shear strength of the bonding area of these samples was determined in push-out tests. Additionally, mechanical testing of segments of the hybrid profiles using shear compression tests was employed to provide information about the influence of different bonding mechanisms on the strength of the composite zone.

As a result of global economic and environmental change, the demand for innovative, environmentally-friendly technologies is increasing. Employing solid lubricants in rolling contacts can reduce the use of environmentally harmful greases and oils. The aim of the current research was the development of a solid lubricant system with regenerative properties. The layer system consisted of a molybdenum (Mo) reservoir and a top layer of molybdenum trioxide (MoO₃). After surface wear, Mo is supposed to react with atmospheric oxygen and form a new oxide. The determination of the wear volume of thin layers cannot be measured microscopically, which is why the wear behavior is initially determined on the nano level. In this work, single Mo and MoO₃ coatings prepared by physical vapor deposition (PVD) are characterized by nano testing. The main objective was to determine the wear volume of the single coatings using a newly developed method considering the initial topology. For this purpose, nano-wear tests with different wear paths and normal forces were carried out and measured by in situ scanning probe microscopy (SPM). Based on the characteristic values determined, the coefficient of wear was determined for wear modeling according to Sarkar. The validation of the wear model developed was carried out by further wear tests on the respective mono layers.

In addition to using conventional lubricants, such as oil and grease, rolling bearings can also be used with a dry lubricant. For example, the use of dry lubricant systems is necessary when the application of oils or greases is not possible (e.g., at high temperatures or in aerospace applications). The requirements of a solid lubricant are to reduce friction and wear of mechanical contact partners. In this work, a molybdenum-based coating system was applied by means of physical vapor deposition (PVD). The coating system consists of a molybdenum (Mo) reservoir with molybdenum trioxide (MoO₃) as the top layer. The MoO₃, which is particularly important for the run-in and the lubricating effect, is intended to continuously regenerate from the reservoir via tribo-oxidation. To determine the friction and wear behavior, cylindrical roller thrust bearings were used. Experiments demonstrated that the lubrication system is effective and that the frictional behavior has been improved. On the one hand, the frictional torque of the rolling bearings has been considerably reduced and, on the other, significantly extended operating times have been determined compared to unlubricated reference experiments. Simultaneously, material analyses have been carried out by means of scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX). The investigations showed that the MoO₃ was transferred to uncoated bearing components. This improved the tribological behavior and reduced abrasive and adhesive wear.

The reinforcement of light metal components with steel allows to increase the strength of the part while keeping the weight comparatively low. Lateral angular co-extrusion (LACE) offers the possibility to produce hybrid coaxial profiles consisting of steel and aluminum. In the present study, the effect of the process parameters temperature, contact pressure and time on the metallurgical bonding process and the development of intermetallic phases was investigated. Therefore, an analogy experiment was developed to reproduce the process conditions during co-extrusion using a forming dilatometer. Based on scanning electron microscopy analysis of the specimens, the intermetallic phase seam thickness was measured to calculate the resulting diffusion coefficients. Nanoindentation and energy dispersive X-ray spectroscopy measurements were carried out to determine the element distribution and estimate properties within the joining zone. The proposed numerical model for the calculation of the resulting intermetallic phase seam width was implemented into a finite element (FE) software using a user-subroutine and validated by experimental results. Using the subroutine, a numerical prediction of the resulting intermetallic phase thicknesses is possible during the tool design, which can be exploited to avoid the weakening of the component strength due to formation of wide intermetallic phase seams.

Within the framework of the Collaborative Research Center 1153, we investigated novel process chains for the production of bulk components with different metals as joining partners. In the present study, the co-extrusion of coaxially reinforced hollow profiles was employed to manufacture semi-finished products for a subsequent die-forging process, which was then used for the manufacture of hybrid bearing bushings. The hybrid hollow profiles, made of the aluminum alloy EN AW-6082 paired with either the case-hardening steel 20MnCr5, the stainless steel X5CrNi18-10, or the rolling bearing steel 100Cr6, were produced by Lateral Angular Co-Extrusion. Push-out tests on hybrid hollow sections over the entire sample cross-section showed shear strengths of 44 MPa ± 8 MPa (100Cr6) up to 63 MPa ± 5 MPa (X5CrNi18-10). In particular, the influence of force and form closure on the joint zone could be determined using specimen segments tested in shear compression. Locally, shear strengths of up to 131 MPa (X5CrNi18-10) were demonstrated in the shear compression test. From these samples, lamellae for microstructural analysis were prepared with a Focused Ion Beam. Detailed analyses showed that for all material combinations, a material bond in the form of an ultra-thin intermetallic phase seam with a thickness of up to 50 nm could be established.

In the context of an ageing society, advancements in medicine and biomedical technology are becoming increasingly important. A major goal is to minimise the number of surgical operations. Magnesium alloys are gaining attention due to their degradable properties, good biocompatibility, and osteoconductivity. However, for implants made from this material to be usable, a precise understanding of the degradation rate and a correspondingly adapted design must be available. This work focuses on constructing a suitable experimental chamber for degradation analysis, as well as investigating the impact of sample positioning on degradation using two different geometries of WE43 alloy for potential use as osteosynthesis implants. Optical and mechanical tests were carried out on these geometries. The tests revealed that the sample positioning in the experimental chamber affects degradation, with the central position yielding the most suitable results for future applications. In addition, mechanical tests demonstrated reduced mechanical properties in the degradation layer. This work provides an initial basis for further investigations into the use of the WE43 alloy as an osteosynthesis implant and supports the numerical calculation of degradation.