Power ultrasonics for additive manufacturing and consolidating of materials

Friel, Ross J.

doi:10.1016/b978-1-78242-028-6.00013-2

Cited by 23 publications

(15 citation statements)

References 27 publications

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“…The efficiency is not exactly zero when not welding because there is a small residual shear force from the calculation (14). Nontheless, the estimated welding efficiency is near estimates for ultrasonic metal welding systems [6] and below that of UAM piezoelectric transducers [40], which is greater than 90%. This estimate is sensible considering efficiency cannot be greater than the ultrasonic transducers themselves.…”

Section: Shear Force Estimates and Welder Efficiencymentioning

confidence: 93%

Dynamics of ultrasonic additive manufacturing

Hehr

Dapino

2017

Ultrasonics

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Ultrasonic additive manufacturing (UAM) is a solid-state technology for joining similar and dissimilar metal foils near room temperature by scrubbing them together with ultrasonic vibrations under pressure. Structural dynamics of the welding assembly and work piece influence how energy is transferred during the process and ultimately, part quality. To understand the effect of structural dynamics during UAM, a linear time-invariant model is proposed to relate the inputs of shear force and electric current to resultant welder velocity and voltage. Measured frequency response and operating performance of the welder under no load is used to identify model parameters. Using this model and in-situ measurements, shear force and welder efficiency are estimated to be near 2000N and 80% when welding Al 6061-H18 weld foil, respectively. Shear force and welder efficiency have never been estimated before in UAM. The influence of processing conditions, i.e., welder amplitude, normal force, and weld speed, on shear force and welder efficiency are investigated. Welder velocity was found to strongly influence the shear force magnitude and efficiency while normal force and weld speed showed little to no influence. The proposed model is used to describe high frequency harmonic content in the velocity response of the welder during welding operations and coupling of the UAM build with the welder.

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Section: Shear Force Estimates and Welder Efficiencymentioning

confidence: 93%

Dynamics of ultrasonic additive manufacturing

Hehr

Dapino

2017

Ultrasonics

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“…is has been explored for applications such as 3D channels for microchannel cooling and cooling channels for molds. Also, during UAM processing, the building process can be interrupted and subsequent machining can be performed [24]. is is extremely difficult while using other manufacturing techniques.…”

Section: Uam Versus Other Am Technologiesmentioning

confidence: 99%

“…However, only a small amount of machining is required since UAM produces a near-net shape build. For this reason, UAM is sometimes referred to as hybrid additive/substantive manufacturing [24]. Compared with the conventional CNC machining, only a little waste or scrap is formed because of machining after UAM.…”

Section: Introductionmentioning

confidence: 99%

Power Ultrasonic Additive Manufacturing: Process Parameters, Microstructure, and Mechanical Properties

Gujba

Medraj

2020

Advances in Materials Science and Engineering

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Additive manufacturing (AM) for fabricating 3D metallic parts has recently received considerable attention. Among the emerging AM technologies is ultrasonic additive manufacturing (UAM) or ultrasonic consolidation (UC), which uses ultrasonic vibrations to bond similar or dissimilar materials to produce 3D builds. This technology has several competitive advantages over other AM technologies, which includes fabrication of dissimilar materials and complex shapes, higher deposition rate, and fabrication at lower temperatures, which results in no material transformation during processing. Although UAM process optimization and microstructure have been reported in the literature, there is still lack of standardized and satisfactory understanding of the mechanical properties of UAM builds. This could be attributed to structural defects associated with UAM processing. This article discusses the effects of UAM process parameters on the resulting microstructure and mechanical properties. Special attention is given to hardness, shear strength, tensile strength, fatigue, and creep measurements. Also, pull-out, push-out, and push-pin tests commonly employed to characterize bond quality and strength have been reviewed. Finally, current challenges and drawbacks of the process and potential applications have been addressed.

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“…This requirement acts to increase the complexity of the manufacturing process. Comparatively, Ultrasonic Additive Manufacturing (UAM) appears to be a viable alternative to previous methods employed due the unique abilities associated with this solid state fabrication process and limited temperature experienced [13].…”

Section: Earlier Work In This Area Were Developed By Weiss and Prinzmentioning

confidence: 99%

Multifunctional metal matrix composites with embedded printed electrical materials fabricated by ultrasonic additive manufacturing

Monaghan

Nguyen

et al. 2017

Composites Part B: Engineering

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This work proposes a new method for the fabrication of Multifunctional Metal Matrix Composite (MMC) structures featuring embedded printed electrical materials through Ultrasonic Additive Manufacturing (UAM). Printed electrical circuitries combining conductive and insulating materials were directly embedded within the interlaminar region of UAM aluminium matrices to realise previously unachievable multifunctional composites. A specific surface flattening process was developed to eliminate the risk of short circuiting between the metal matrices and printed conductors, and simultaneously reduce the total thickness of the printed circuitry. This acted to improve the integrity of the UAM MMC's and their resultant mechanical strength. The functionality of embedded printed circuitries was examined via four-point probe measurement.DualBeam Scanning Electron Microscopy (SEM) and Focused Ion Beam (FIB) milling were used to investigate the microstructures of conductive materials to characterize the effect of UAM embedding energy whilst peel testing was used to quantify mechanical strength of MMC structures in combination with optical microscopy. Through this process, fully functioning MMC structures featuring embedded insulating and conductive materials were realised whilst still maintaining high peel resistances of ca. 70 N and linear weld densities of ca. 90%.

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Power ultrasonics for additive manufacturing and consolidating of materials

Cited by 23 publications

References 27 publications

Dynamics of ultrasonic additive manufacturing

Dynamics of ultrasonic additive manufacturing

Power Ultrasonic Additive Manufacturing: Process Parameters, Microstructure, and Mechanical Properties

Multifunctional metal matrix composites with embedded printed electrical materials fabricated by ultrasonic additive manufacturing

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