Influence of thin-film coatings on the joining process of shaft-hub connections

With the ongoing electrification of vehicles and the resulting demand for higher power densities, drivetrain requirements are becoming increasingly stringent. Shaft-hub connections are particularly affected in terms of both quantity and design, making innovative solutions necessary. A key factor in meeting these requirements is knowledge of the stress state within the contact area. One promising approach is the application of a thin-film-based sensor system directly onto the shaft surface. This enables, for the first time, the direct measurement of contact pressure in the interface, allowing for more precise connection design. To fully exploit the potential of this sensor technology, its influence on the joining process of shaft-hub connections must be investigated. In this study, cylindrical interference-fits were coated with two thin-film systems relevant to the application, followed by joining tests. The resulting damage was analyzed to derive general recommendations for the joining of coated shaft-hub connections. The results show that shrink-fitting enables damage-free joining, provided specific parameters are met, as confirmed by experimental testing and microscopic examination. This not only preserves the integrity of the sensor system but also establishes the prerequisite for potential in situ measurements, thereby laying the foundation for the feasibility of direct load monitoring during operation.