Design and Application of a Standardized Test Rig for Characterizing Hybrid Orbital Formed Components

Abstract The demand for lightweight multi-material systems, particularly in powertrain applications for electric mobility, necessitates efficient manufacturing and joining technologies. Orbital forming, a commonly applied process in bulk and sheet-bulk metal forming, enables the manufacturing of hybrid components in a single forming and joining step, creating the joint within the sheet plane. Despite this, standardized methods for evaluating the load-bearing capacity of such joints are not yet established. Existing investigations, which primarily consist of push-out tests, do not adequately represent the realistic load conditions acting on drivetrain components, such as those induced by a bicycle chain. This research presents the elaboration and implementation of a novel modular test rig designed for integration with a universal testing machine. The test rig facilitates the application of tensile loads through a bicycle chain under adjustable angles between 0° and 12°. The design includes a dual clamping mechanism, comprising a central high-strength screw for axial force transmission and a machined hexagonal interface for torsional load transfer, preventing specimen slippage under torque. The functionality of the setup is demonstrated through static and dynamic load tests on hybrid components made of DP600 steel and EN AW-7075 aluminum. The experimental tests conducted in this study have validated the reliable application of load and have provided insights into the characteristic deformation and failure behavior of the hybrid components. These observations form the basis for further analysis of structural response and joint performance.