ZIM project “BainMa Shaft”: Development of a sequentially induction-hardened cardan shaft with a high-strength surface layer by locally load-dependent bainite-martensite components and low-impact post-processing to increase lifetime

M.Sc. Benjamin Dollhofer

Motivation

Induction surface hardening is an important tool in modern gear manufacturing to increase fatigue strength as well as wear resistance of individual components in an energy-efficient and cost-efficient way. It has already been shown in the past that a mixed structure of bainite and martensite in certain volume ratios can lead to improved fatigue properties and better component behavior in operation. Improvements to this process should enable induction heat treatment of complex geometries to meet their requirements and thus expand the range of applications for induction surface hardening.

Goals

• Improvement of the controlled heat treatment in induction hardening
• Establishing a bainitic-martensitic mixed microstructure for complex geometries depending on the operating requirements of the

Investigations

• Experimental investigations of phase transformations and the resulting mechanical properties
• Synthesize material data and process parameters for the development of a simulation model of complex geometries
• Realization of application-related component tests