Statistical Characterization of Ultrasonic Additive Manufacturing Ti/Al Composites

2010 ◽  
Vol 132 (4) ◽  
Author(s):  
C. D. Hopkins ◽  
M. J. Dapino ◽  
S. A. Fernandez
Keyword(s):  
Additive Manufacturing ◽  
Bond Strength ◽  
Mechanical Strength ◽  
Normal Force ◽  
Oscillation Amplitude ◽  
Metal Foil ◽  
Bond Quality ◽  
Statistical Characterization ◽  
Ultrasonic Additive Manufacturing ◽  
Transverse Tensile

Ultrasonic additive manufacturing (UAM) is an emerging solid-state fabrication process that can be used for layered creation of solid metal structures. In UAM, ultrasonic energy is used to induce plastic deformation and nascent surface formation at the interface between layers of metal foil, thus creating bonding between the layers. UAM is an inherently stochastic process with a number of unknown facets that can affect the bond quality. In order to take advantage of the unique benefits of UAM, it is necessary to understand the relationship between manufacturing parameters (machine settings) and bond quality by quantifying the mechanical strength of UAM builds. This research identifies the optimum combination of processing parameters, including normal force, oscillation amplitude, weld speed, and number of bilayers for the manufacture of commercially pure, grade 1 titanium+1100-O aluminum composites. A multifactorial experiment was designed to study the effect of the above factors on the outcome measures ultimate shear strength and ultimate transverse tensile strength. Generalized linear models were used to study the statistical significance of each factor. For a given factor, the operating levels were selected to cover the full range of machine capabilities. Transverse shear and transverse tensile experiments were conducted to quantify the bond strength of the builds. Optimum levels of each parameter were established based on statistical contrast trend analyses. The results from these analyses indicate that high mechanical strength can be achieved with a process window bounded by a 1500 N normal force, 30 μm oscillation amplitude, about 42 mm/s weld speed, and two bilayers. The effects of each process parameter on bond strength are discussed and explained.

Optimizing Ultrasonic Additive Manufactured Al 3003 Properties With Statistical Modeling

2011 ◽  
Vol 134 (1) ◽  
Author(s):  
C. D. Hopkins ◽  
P. J. Wolcott ◽  
M. J. Dapino ◽  
A. G. Truog ◽  
S. S. Babu ◽  
...  
Keyword(s):  
Mechanical Strength ◽  
Process Parameters ◽  
Oscillation Amplitude ◽  
Ductile Failure ◽  
Process Window ◽  
Ultimate Shear Strength ◽  
Ultrasonic Additive Manufacturing ◽  
Transverse Tensile ◽  
Scanning Electronmicroscopy ◽  
Transverse Tensile Strength

Ultrasonic additive manufacturing (UAM) has proven useful in the solid-state, low tempe’rature fabrication of layered solid metal structures. It is necessary to optimize the various process variables that affect the quality of bonding between layers through investigation of the mechanical strength of various UAM builds. We investigate the effect of the process parameters tack force, weld force, oscillation amplitude, and weld rate on the ultimate shear strength (USS) and ultimate transverse tensile strength (UTTS) of 3003-H18 aluminum UAM built samples. A multifactorial experiment was designed and an analysis of variance was performed to obtain an optimal set of process parameters for maximizing mechanical strength for the tested factors. The statistical analyses indicate that a relatively high mechanical strength can be achieved with a process window bounded by a 350 N tack force, 1000 N weld force, 26 μm oscillation amplitude, and about 42 mm/s weld rate. Optical analyses of bond characterization did not show a consistent correlation linking linear weld density and bonded area of fractured surfaces to mechanical strength. Therefore, scanning electronmicroscopy (SEM) was conducted on fractured samples showing a good correlation between mechanical strength and area fraction that shows ductile failure.

Effect of process parameters on interfacial temperature and shear strength of ultrasonic additive manufacturing of carbon steel 4130

2021 ◽  
pp. 1-10
Author(s):  
Tianyang Han ◽  
Leon M Headings ◽  
Ryan Hahnlen ◽  
Marcelo J. Dapino
Keyword(s):  
Shear Strength ◽  
Additive Manufacturing ◽  
Carbon Steel ◽  
Welding Speed ◽  
Normal Force ◽  
Pearson Correlation ◽  
Process Window ◽  
Ultrasonic Additive Manufacturing ◽  
Interfacial Temperature ◽  
Weld Parameters

Abstract Ultrasonic additive manufacturing (UAM) is a solid state manufacturing process capable of producing near-net-shape metal parts. Recent studies have shown the promise of UAM welding of high strength steels. However, the effect of weld parameters on the weld quality of UAM steel is unclear. A design of experiments study based on a Taguchi L16 design array was conducted to investigate the influence of parameters including baseplate temperature, amplitude, welding speed, and normal force on the interfacial temperature and shear strength of UAM welding of carbon steel 4130. Analysis of variance (ANOVA) and main effects analyses were performed to determine optimal weld parameters within the process window. A Pearson correlation test was conducted to find the relationship between interfacial temperature and shear strength. These analyses indicate that the highest shear strength of 392.8 MPa can be achieved by using a baseplate temperature of 400°F (204.4°C), amplitude of 31.5 μm, welding speed of 40 in/min (16.93 mm/s), and normal force of 6000 N. The Pearson correlation coefficient is calculated as 0.227, which indicates a weak positive correlation between interfacial temperature and shear strength over the range tested.

Stick-Slip Dynamics in Ultrasonic Additive Manufacturing

2012 ◽  
Author(s):  
James M. Gibert ◽  
Georges M. Fadel ◽  
Mohammed F. Daqaq
Keyword(s):  
Additive Manufacturing ◽  
Metal Foil ◽  
Critical Height ◽  
Stick Slip ◽  
Ultrasonic Additive Manufacturing ◽  
Resonant Interactions ◽  
Lumped Parameter ◽  
Friction Oscillator ◽  
Interfacial Motion ◽  
Experimental Findings

Ultrasonic Additive Manufacturing is a solid state manufacturing process that combines ultrasonic welding of layers of thin metal foil with contour milling. Bonding between two foils is accomplished by holding the foils together under pressure and applying high-frequency excitations normal to the pressure direction. The accepted explanation for bonding is that stresses due to both compression and friction stemming from the interfacial motion between the foils result in plasticity and ultimately produce a metallurgical bond. The process however, has been shown to have a critical shortcoming in its operation; namely, the presence of a range of build heights within which bonding cannot be initiated. To better understand the reasons for this anomaly, this paper simplifies the process into a lumped parameter dry friction oscillator and shows that complex stick-slip motions of the build feature near or above its resonance frequency may explain bond degradation. Specifically, it is shown through bifurcation maps obtained for different process parameters that, at the critical build heights, the feature exhibits pure stick motions due to primary resonant interactions between the external excitation and the feature. Furthermore, complex aperiodic responses are observed at build heights above resonance (short features). In such scenarios, bonding cannot be initiated because no or non-uniform interfacial motions occur between the tape and the feature. It is also observed that, once the height of the build feature increases beyond the critical value corresponding to resonance, periodic uniform responses essential for bonding, are recovered. These results corroborates previous experimental findings which demonstrate that bonding can be hard to initiate near or slightly above resonance (at or slightly below a critical height) but can be reinitiated below resonance (above the critical height).

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

2020 ◽  
Vol 2020 ◽  
pp. 1-17
Author(s):  
Abdullahi K. Gujba ◽  
Mamoun Medraj
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Process Parameters ◽  
Dissimilar Materials ◽  
Structural Defects ◽  
Bond Quality ◽  
Ultrasonic Additive Manufacturing ◽  
Pull Out ◽  
Microstructure And Mechanical Properties ◽  
Metallic Parts

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.

Transient thermal response in ultrasonic additive manufacturing of aluminum 3003

2011 ◽  
Vol 17 (5) ◽  
pp. 369-379 ◽  
Author(s):  
David Schick ◽  
Sudarsanam Suresh Babu ◽  
Daniel R. Foster ◽  
Marcelo Dapino ◽  
Matt Short ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Thermal Response ◽  
Ultrasonic Additive Manufacturing ◽  
Transient Thermal ◽  
Transient Thermal Response

Sol-Gel Coating Facilitating Si-to-Si Wafer Bonding at Low Temperature

2005 ◽  
Author(s):  
J. Wei ◽  
S. S. Deng ◽  
C. M. Tan
Keyword(s):  
Low Temperature ◽  
Bond Strength ◽  
Wafer Bonding ◽  
Intermediate Layer ◽  
Bonding Temperature ◽  
Sol Gel ◽  
Bond Quality ◽  
Bubble Generation ◽  
High Bond ◽  
High Bond Strength

Silicon-to-silicon wafer bonding by sol-gel intermediate layer has been performed using acid-catalyzed tetraethylthosilicate-ethanol-water sol solution. High bond strength near to the fracture strength of bulk silicon is obtained at low temperature, for example 100°C. However, The bond efficiency and bond strength of this intermediate layer bonding sharply decrease when the bonding temperature increases to elevated temperature, such as 300 °C. The degradation of bond quality is found to be related to the decomposition of residual organic species at elevated bonding temperature. The bubble generation and the mechanism of the high bond strength at low temperature are exploited.

scholarly journals Investigation of the Impact of Micro-Structuring on the Bonding Performance of Beechwood (Fagus Sylvatica L.)

Forests ◽  
2022 ◽  
Vol 13 (1) ◽  
pp. 113
Author(s):  
Destin Bamokina Moanda ◽  
Martin Lehmann ◽  
Peter Niemz
Keyword(s):  
Bond Strength ◽  
Waiting Time ◽  
Type I ◽  
Bond Quality ◽  
Structured Surfaces ◽  
Structured Surface ◽  
Bonding Performance ◽  
Delamination Resistance ◽  
Micro Structuring ◽  
The Impact

Although glueing softwood is well mastered by the industry, predicting and controlling bond quality for hardwood is still challenging after years of research. Parameters such as the adhesive type, resin–hardener ratio, and the penetration behaviour of the wood are determinants for the bond quality. The aim of this work was to assess to what extent the glueing behaviour of beechwood can be improved by using structural planing. The different surfacing methods were characterised by their roughness. The bond strength of the micro-structured surfaces was determined according to EN 302-1, and the delamination resistance was tested as indicated by EN 302-2 for type I adhesives. Micro-structured surfaces were compared with different surfaces (generated by surfacing methods such as dull/sharp planing and sanding). In dry test conditions, all surfacing methods gave satisfying results. In the wet stage, the bond strength on the finer micro-structured surface slightly outperformed the coarse structure surface. For the delamination resistance, a clear improvement could be observed for melamine-formaldehyde-bonded specimens since, when using the recommended amount of adhesive, micro-structured surfaces fulfilled the requirements. Nevertheless, structural planing cannot lead to a reduction in the applied grammage since no sample with a smaller amount fulfilled EN 302-2 requirements even by observing the recommended closed assembly waiting time. Adhesion area enlargement of the micro-structuring is minor. The good delamination performance without waiting time (CAT) is not caused by surface enlargement, since finer micro-structured surface with negligible area increase and delivered even better delamination resistance. Subsurface analysis should be carried out to thoroughly investigate this phenomenon.

Thermomechanical Behavior of Low CTE Metal-Matrix Composites Fabricated Through Ultrasonic Additive Manufacturing

2012 ◽  
Author(s):  
Ryan Hahnlen ◽  
Marcelo J. Dapino
Keyword(s):  
Shear Strength ◽  
Additive Manufacturing ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Volume Fraction ◽  
Large Strain ◽  
Matrix Composites ◽  
Interface Shear ◽  
Mechanical Coupling ◽  
Ultrasonic Additive Manufacturing

Shape memory and superelastic NiTi are often utilized for their large strain recovery and actuation properties. The objective of this research is to utilize the stresses generated by pre-strained NiTi as it is heated in order to tailor the CTE of metal-matrix composites. The composites studied consist of an Al 3003-H18 matrix with embedded NiTi ribbons fabricated through an emerging rapid prototyping process called Ultrasonic Additive Manufacturing (UAM). The thermally-induced strain of the composites is characterized and results show that the two key parameters in adjusting the effective CTE are the NiTi volume fraction and prestrain of the embedded NiTi. From the observed behavior, a constitutive composite model is developed based constitutive SMA models and strain matching composite models. Additional composites were fabricated to characterize the NiTi-Al interface through EDS and DSC. These methods were used to investigate the possibility of metallurgical bonding between the ribbon and matrix and determine interface shear strength. Interface investigation indicates that mechanical coupling is accomplished primarily through friction and the shear strength of the interface is 7.28 MPa. Finally, using the developed model, a composite was designed and fabricated to achieve a near zero CTE. The model suggests that the finished composite will have a zero CTE at a temperature of 135°C.

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