September 14, 2011

Additive Manufacturing Techniques for Dissimilar Materials - VHPUAM

Josh GeorgeApplications Engineer, UltrasonicsEmail: jgeorge@ewi.orgPhone: 614.688.5057

Overview

Highlight UAM process Very high-power UAM

system status Current developments –

UAM bonding, smart structures

New VHP research platform

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

Rotating Transducer, Booster, Horn System

Transducer Booster Horn‘Dummy’Booster

Al Base Plate

Anvil

Al Tape

US vibrations from transducer

Welded tape

US vibrations of ‘horn’

… a bit more detail

US Weld

US horn – has textured surface to grip tape

… detail …

Laying of tapes side-by-side, then layer-by-layer to build a solid plate

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

Current Machine Status

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)

9-kW Weld Module

Features

Multi-axis, “Speed Bump” feature

9-kW “Push – Pull”Machining center with automatic tool changer

Tape feed system accommodates up to 12-in. sheet

Process, Operation

CAD Model Machine CodeFabrication

Example Products

Rapid Prototyping Thermal ManagementMetal Matrix Composites

Dissimilar Metal LaminatesEmbedded Electronics

Complex Geometry

Embedded Sensors Integrated Systems

Dissimilar Matrix Potential

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

Cu

Al

SiC fiber

Material pair proven for ultrasonic welding

Material pair tested for ultrasonic spot weld

10

Al Be Cu Ge Au Fe Mg Mo Ni Pd Pt Si Ag Ta Sn Ti W ZrAl Alloys

Be Alloys Cu Alloys

Ge Au

Fe Alloys Mg Alloys

Mo alloys Ni Alloys

Pd Pt Alloys

Si Ag Alloys

Ta Alloys Sn

Ti Alloys W Alloys

Zr Alloys

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

Metallurgy

Peak temperatures < 0.5T melt

Extensive increase in interface stored

energy

Local formation of nano-grain colonies.

Plastic-flow morphology

12

100 µm

Bulk Tape

Bond Area

OIMSEM

Smart Materials, Structures Early embedding observations Has led development of Adaptive Metal Matrix SMA

Composites

0.003-in.-Diameter NiTi Wire (400×)

381-μm-Diameter NiTi Wire

100 μm4- × 100-μm-Diameter NiTi Wires

2- × 76-μm-Diameter NiTi Wires

1000 μm

100 μm

300 μm

254-μm-Thick NiTi Ribbon

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

Application – Dimensionally Stable NiTi/Al Composites

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

Research Platform

Specifications 2500-lb load 4.5- or 9-kW power 20 ×12 × 6 in. 200 ipm

Available Fall 2011

Questions?Josh GeorgeApplications Engineer, UltrasonicsE-mail: jgeorge@ewi.orgPhone: 614.688.5057