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.

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.

scholarly journals Optimization of molding process parameters for CF/PEEK composites based on Taguchi method

2021 ◽  
Vol 30 ◽  
pp. 263498332110018
Author(s):  
Guangming Dai ◽  
Lihua Zhan ◽  
Chenglong Guan ◽  
Minghui Huang
Keyword(s):  
Tensile Strength ◽  
Process Parameters ◽  
Holding Time ◽  
Thermoplastic Composites ◽  
Molding Pressure ◽  
Molding Process ◽  
Molding Temperature ◽  
Transverse Tensile ◽  
Peek Composite ◽  
Transverse Tensile Strength

In this article, nine groups of laminates were prepared according to the Taguchi L9(33) test array to study the influence of three process parameters, including molding pressure, molding temperature, and holding time on the performance of unidirectional carbon fiber/polyetheretherketone (CF/PEEK) laminates. A differential scanning calorimetry test was employed to select a reasonable process parameters range. The transverse tensile strength of the laminates was measured, and the fiber–matrix interfacial bonding behavior of the tested samples was analyzed by scanning electron microscopy. The results showed that the significance of factors to transverse tensile strength were molding temperature, holding time, and molding pressure in sequence. The optimal molding process parameters for CF/PEEK composite laminate were molding temperature of 400°C, molding pressure of 3 MPa, and holding time of 30 min. The optimization results were meaningful for the extension and application of thermoplastic composites.

Über die mechanische Bedeutung der Holzstrahlen | The mechanical relevance of wood rays

2003 ◽  
Vol 154 (12) ◽  
pp. 498-503 ◽  
Author(s):  
Ingo Burgert
Keyword(s):  
Beech Wood ◽  
Tensile Tests ◽  
Deciduous Tree ◽  
Biological Design ◽  
Transverse Tensile ◽  
Radial Reinforcement ◽  
Radial Strength ◽  
Transverse Tensile Strength ◽  
Strength And Stiffness ◽  
Technical Solutions

Three investigations into the mechanical relevance of wood rays were combined for this article. The main objective was to show, that, apart from physiological functions, rays also significantly influence the radial strength and stiffness of wood. In the first approach twelve deciduous tree species with various proportions of fractions of rays were examined for their transverse tensile strength and stiffness. The second approach was based on the comparison of the radial mechanical properties of wood with a very high proportion of fraction of rays and beech wood with a normal volume. In these two investigations the mechanical relevance of rays could only be deduced indirectly. By isolating big rays of beech and carrying out tensile tests on the tissue, we found direct evidence for the mechanical relevance. The results are discussed with regard to their biomechanical relevance. The importance of a radial reinforcement for the wood is underlined. Moreover, the principle of multi-functionality in nature is emphasized in keeping with a possible transfer of biological design to technical solutions.

scholarly journals Analysis of the Downscaling Effect and Definition of the Process Fingerprints in Micro Injection of Spiral Geometries

Micromachines ◽  
2019 ◽  
Vol 10 (5) ◽  
pp. 335 ◽  
Author(s):  
Antonio Luca ◽  
Oltmann Riemer
Keyword(s):  
Correlation Analysis ◽  
Process Parameters ◽  
Cross Sections ◽  
Mass Production ◽  
Process Window ◽  
Response Variable ◽  
Process Indicators ◽  
Flow Length ◽  
Definition Of ◽  
Microinjection Moulding

Microinjection moulding has been developed to fulfil the needs of mass production of micro components in different fields. A challenge of this technology lies in the downscaling of micro components, which leads to faster solidification of the polymeric material and a narrower process window. Moreover, the small cavity dimensions represent a limit for process monitoring due to the inability to install in-cavity sensors. Therefore, new solutions must be found. In this study, the downscaling effect was investigated by means of three spiral geometries with different cross sections, considering the achievable flow length as a response variable. Process indicators, called “process fingerprints”, were defined to monitor the process in-line. In the first stage, a relationship between the achievable flow length and the process parameters, as well as between the process fingerprints and the process parameters, was established. Subsequently, a correlation analysis was carried out to find the process indicators that are mostly related to the achievable flow length.

An Experimental Determination of Optimum Processing Parameters for Al∕SiC Metal Matrix Composites Made Using Ultrasonic Consolidation

2007 ◽  
Vol 129 (4) ◽  
pp. 538-549 ◽  
Author(s):  
Y. Yang ◽  
G. D. Janaki Ram ◽  
B. E. Stucker
Keyword(s):  
Bond Strength ◽  
Metal Matrix Composites ◽  
Process Parameters ◽  
Metal Matrix ◽  
Oscillation Amplitude ◽  
Processing Parameters ◽  
Optimum Combination ◽  
Matrix Composites ◽  
Ultrasonic Consolidation ◽  
Push Out

Ultrasonic consolidation, an emerging additive manufacturing technology, is one of the most recent technologies considered for fabrication of metal matrix composites (MMCs). This study was performed to identify the optimum combination of processing parameters, including oscillation amplitude, welding speed, normal force, operating temperature, and fiber orientation, for manufacture of long-fiber-reinforced MMCs. A design of experiments approach (Taguchi L25 orthogonal array) was adopted to statistically determine the influences of individual process parameters. SiC fibers of 0.1mm diameter were successfully embedded into an Al 3003 metal matrix. Push-out testing was employed to evaluate the bond strength between the fiber and the matrix. Data from push-out tests and microstructural studies were analyzed and an optimum combination of parameters was achieved. The effects of process parameters on bond formation and fiber/matrix bond strength are discussed.

Impact of quasi-isotropic raster layup on the mechanical behaviour of fused filament fabrication parts

2021 ◽  
pp. 095400832110419
Author(s):  
Lovin K John ◽  
Ramu Murugan ◽  
Sarat Singamneni
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Mechanical Strength ◽  
Process Parameters ◽  
Mechanical Behaviour ◽  
Fused Filament Fabrication ◽  
Anisotropic Behaviour ◽  
Oriented Samples ◽  
Weak Interlayer ◽  
Special Concern

The development of fused filament fabrication has extended the range of application of additive manufacturing in various areas of research. However, the mechanical strength of the fused filament fabrication–printed parts were considerably lower than that of parts fabricated by other conventional methods, owing to the observed anisotropic behaviour and formation of voids by weak interlayer diffusion. Intense studies on the effect of design and process parameters of the printed parts on the mechanical properties have been done, whereas studies on the effect of build orientations and raster patterns needs special concern. The main aim of this work is to fabricate parts printed using quasi-isotropic laminate arrangement of rasters, achieved by a raster layup of [45/0/−45/90]s, and to compare their mechanical properties with those of the commonly used 0°/90° (cross) and 45°/−45° (crisscross) raster oriented parts. The quasi-isotropic–oriented samples were observed with improved mechanical behaviour in tensile, compressive, flexural and impact tests compared to the commonly employed raster orientations.

Experimental reexamination of transverse tensile strength for IM7/8552 tape-laminate composites

2020 ◽  
Vol 54 (23) ◽  
pp. 3297-3312
Author(s):  
Caitlin M Arndt ◽  
Nelson V de Carvalho ◽  
Michael W Czabaj
Keyword(s):  
Tensile Strength ◽  
Weak Link ◽  
Surface Preparation ◽  
Test Method ◽  
Transverse Fracture ◽  
Laminate Composites ◽  
Transverse Tensile ◽  
Specimen Volume ◽  
Transverse Tensile Strength

Due to the observed dependence of transverse-tensile strength, Y T, on test geometry and specimen size, there is no consensus regarding a test method that can uniquely measure Y T. This study reexamines the characterization of Y T by comparing results from established flexure tests with results from a new tensile test that exhibits consistent failure in the gage region. Additionally, the effects of surface preparation and direction of transverse fracture are investigated. Results show that Y T is inversely proportional to specimen volume and surface roughness and is insensitive to direction of transverse fracture. The relationship between specimen volume and Y T is adequately captured by Weibull strength-scaling theory, except at the tails of the Y T distributions. However, specimens exhibited microcracking prior to failure, which violates the “weak-link” assumption of the Weibull theory. These findings highlight the challenges of using deterministic Y T values in progressive damage analysis.

scholarly journals Construction of Process Window to Predict Hardness in Tailored Tool Thermomechanical Treatment and its Application

Metals ◽  
2019 ◽  
Vol 9 (1) ◽  
pp. 50
Author(s):  
Jae-Hong Kim ◽  
Seon-Bong Lee ◽  
Byung-Min Kim
Keyword(s):  
Thermomechanical Treatment ◽  
Process Parameters ◽  
Hot Stamping ◽  
Process Window ◽  
Shaped Part ◽  
Hardness Prediction ◽  
Artificial Neural Network Ann ◽  
Quench Factor Analysis ◽  
Good Agreement

Recently, in order to improve crashworthiness and achieve weight reduction of car body, a hot stamping process has been applied to the production of the part with tailored properties using tailored tool thermomechanical treatment. In the tailored tool thermomechanical treatment process, process parameters influence the mechanical properties of final product such as strength and hardness. Therefore, the prediction of hardness for final product is very important to manufacture hot-stamped part considering various process parameters. The purpose of this study is to propose a process window, which can predict hardness for various process parameters in tailored tool thermomechanical treatment. To determine the process window, finite element (FE) simulation coupled with quench factor analysis (QFA) has been performed for combinations of various process parameters. Subsequently, the process window was constructed through the training of artificial neural network (ANN) and experiment of tailored tool thermomechanical treatment for hat-shaped part was performed to verify effectiveness of hardness prediction. Then, the process parameters were determined from process window for hot stamping of the hat-shaped part with the required distribution of hardness. Hardness predicted by process window was in good agreement with measured one within 3.1% error in additional experiment. Therefore, the suggested process window can be used efficiently for hardness prediction and determination of process parameters in tailored tool thermomechanical treatment of hot-stamping parts.

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