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Reducing Material Transfer in Hot Stamping of Aluminum via the Synergy Between Self-Lubricating Claddings and High-Temperature Lubricants

The hot stamping process for aluminium alloys has gained significant traction in recent years due to its potential for lightweighting in automotive components. However, achieving high-quality stamped parts with complex geometries requires precise control over surface interactions between the tooling and the workpiece. This study delves into the combined role of coatings and lubricants for optimizing the tribological interaction in the hot stamping process for aluminium alloys, with particular emphasis on the synergistic effects observed when employing a self-lubricating laser cladding in combination with a graphite containing high temperature lubricant. Three surface conditions were studied: an uncoated hot work tool steel, a laser deposited NiCrSiB cladding, and the same cladding containing lubricious aggregates of Ag/MoS2. All surfaces were manually ground to a surface roughness Sa 0.3-0.4 £gm. A commercially available graphite-based lubricant was applied on the surface of the tools prior to the tribological tests. Strip-drawing tribological tests with an Al alloy strip temperature of 300 „aC revealed a significant contrast between coated and uncoated tool steels. Uncoated tool steels exhibited early lubricant failure, as seen by occurrence of aluminium adhesion, regardless of testing condition or amount of lubricant used. The cladding without the lubricious aggregates increased the distance before failure by 85%, and by 200% when the lubricious phases were present in the cladding. Similar behaviour was observed for the cladding containing Ag/MoS2 when sliding at 50 mm/s and 100 mm/s. At room temperature, similar behaviour was observed for the uncoated and coated tool steels, but in this case, the average coefficient of friction (CoF) was higher (0.24) compared to the tests at higher temperature (0.15). This work highlights the potential of coatings and lubricants in optimising the hot stamping process for aluminium alloys. The observed synergy between a selflubricating cladding and a graphite containing lubricant presents a promising solution for friction control, wear minimisation, and reduction of tool maintenance in hot stamping of aluminium alloys.

DOI Number: 10.33313/512/A1001
Product:
2024 CHS2 Conference Proceedings
PR-512-A1001
Leonardo Pelcastre, Jens Hardell, Manel Rodriguez Ripoll
May 27, 2024
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