Evaluation of manufacturing processes for the production of graded ultrafine grained materials

Scientific research results show that graded ultrafine grained aluminum-based materials offer technical advantages by possible material property improvements (e.g. yield strength, corrosion resistance) especially when applied to heavily stressed components like screws. The commercial screw production is currently conducted without gradation of the semi-finished workpiece. Until now there is no evaluation on whether and under which conditions graded materials (screws) can technically and economically compete with conventional materials. In this paper, an innovative process chain for the production of graded ultrafine grained components is presented and analyzed based on a methodology for an integrated technical-economic evaluation. The evaluation especially of the yield strength of graded materials, energy consumption of the forming steps, energy costs, and revenue effects of improved material properties will outline the technical and economic potential of the technology. Despite higher energy consumptions positive profit effects can be expected due to improved material properties.