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Ultrasonic Additive Manufacturing for Dissimilar Materials

Explore the innovative Ultrasonic Additive Manufacturing (UAM) process for creating net-shape metal parts using ultrasonic metal welding and CNC milling. Learn about UAM bonding, smart structures, and the latest VHP research platform. Discover the potential of dissimilar material pairings and integrated systems.

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Ultrasonic Additive Manufacturing for Dissimilar Materials

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  1. Additive Manufacturing Techniques for Dissimilar Materials - VHPUAM September 14, 2011 Josh George Applications Engineer, Ultrasonics Email: jgeorge@ewi.org Phone: 614.688.5057

  2. Overview • Highlight UAM process • Very high-power UAM system status • Current developments – UAM bonding, smart structures • New VHP research platform

  3. ‘Dummy’ Booster Transducer Booster Horn Al Tape Rotating Transducer, Booster, Horn System Al Base Plate Anvil Ultrasonic Additive Manufacturing* … a new technology – “UAM” creates net-shape solid metal parts using: solid state ultrasonic metal welding and CNC contour milling * UAM – aka Ultrasonic Consolidation

  4. … a bit more detail US horn – has textured surface to grip tape US vibrations from transducer US Weld Welded tape US vibrations of ‘horn’

  5. … detail … • In practice, tapes are first laid side-by-side, and then built up layer-by-layer to build a solid metal plate Each tape layer staggered from one below so seams do not line up. In practice, there are no gaps between adjacent tapes Laying of tapes side-by-side, then layer-by-layer to build a solid plate

  6. Current Machine Status 9-kW Weld Module • Materials – High power ability to weld Cu, Ni, stainless steel • Part Size – Working envelope of 6- × 6- × 3-feet tall • Speed – Welding speeds up to 400 in./minute with integrated CNC machining at up to 600 in./minute (example: 6”x6”x6” at 150 in./minute would take 33 hours)

  7. Features Machining center with automatic tool changer Tape feed system accommodates up to 12-in. sheet 9-kW “Push – Pull” Multi-axis, “Speed Bump” feature

  8. Process, Operation Fabrication CAD Model Machine Code

  9. Example Products Metal Matrix Composites Rapid Prototyping Thermal Management Complex Geometry Integrated Systems Embedded Electronics Dissimilar Metal Laminates Embedded Sensors

  10. Dissimilar Matrix Potential Material pair proven for ultrasonic welding Al Be Cu Ge Au Fe Mg Mo Ni Pd Pt Si Ag Ta Sn Ti W Zr Al Alloys l l l l l l l l l l l l l l l l l l Be Alloys l l l l Material pair tested for ultrasonic spot weld Cu Alloys l l l l l l l l l l l l l Ge l l Au l l l l l l l l l l Fe Alloys l l l l l l l l l Mg Alloys l l l Mo alloys l l l l l l l Ni Alloys l l l l l l Pd l l l Pt Alloys l l l l l Si l l Ag Alloys l l l Ta Alloys l l l Sn l Ti Alloys l l W Alloys l Zr Alloys l Al SiC fiber Cu • Process well suited to dissimilar metals and multi-material laminate • No liquid phase metallurgical incompatibilities • Multiple metal foils can be combined • Fiberoptic, B, and SiC fibers can be embedded without deleterious reactions with Al matrix 10

  11. UAM Bonding • Extensive metallurgy studies; e.g., work with 3003 – evidence of recrystallization as bonding mechanism (a) and (b); heat buildup causes more extensive effect at top. • Materials investigated: - 110 Cu (>99.0% Cu), hard condition - 3003 Al, H18 (strain-hardened) - 6061 Al, H18 (strain-hardened) - 304L SS (annealed) Original interface

  12. Metallurgy Peak temperatures < 0.5T melt Extensive increase in interface stored energy Local formation of nano-grain colonies. Plastic-flow morphology OIM SEM Bulk Tape Bond Area 100 µm 12

  13. 100 μm 381-μm-Diameter NiTi Wire Smart Materials, Structures • Early embedding observations • Has led development of Adaptive Metal Matrix SMA Composites 300 μm 0.003-in.-Diameter NiTi Wire (400×) 254-μm-Thick NiTi Ribbon 1000 μm 2- × 76-μm-Diameter NiTi Wires 100 μm 4- × 100-μm-Diameter NiTi Wires

  14. Application – Dimensionally Stable NiTi/Al Composites • Aluminum alloys have a high CTE (25.1 ppm/oC) • Thermally induced contraction of embedded NiTi can offset the thermal strain of the Al matrix • NiTi/Al composites could maintain dimensional tolerances over an expanded temperature range Strain vs. Temperature for Sample 3

  15. Next Steps New Commercial Entity to Commercialize Fabrisonic LLC Based in Columbus, OH Selling Machines and UAM Parts University/Lab User Group Stimulate further research in UAM

  16. Research Platform Specifications • 2500-lb load • 4.5- or 9-kW power • 20 ×12 × 6 in. • 200 ipm • Available Fall 2011

  17. Questions? Josh George Applications Engineer, Ultrasonics E-mail: jgeorge@ewi.org Phone: 614.688.5057

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