Abstract
A new process combining cold forging and deep drawing is introduced for forming multi-material components. The components consist of a cold extruded core with a deep drawn and redrawn cup acting as shell. Process mechanics, failures, and process window are investigated for a steel-aluminium pairing. The joining mechanisms between the steel shell and the aluminium core is of force- and form-fit type. The joining strength is larger than 40% of the shear yield stress of the weakest material. Alternative material pairings, chip-cores, double stepped shafts, and deep drawing with sequential backward cup-extrusion, are explored demonstrating the technological potential of the process.
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