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Book Chapter
Ultrasonic Additive Manufacturing
Available to PurchaseSeries: ASM Handbook
Volume: 24
Publisher: ASM International
Published: 15 June 2020
DOI: 10.31399/asm.hb.v24.a0006574
EISBN: 978-1-62708-290-7
... Abstract Ultrasonic additive manufacturing (UAM) is a solid-state hybrid manufacturing technique that leverages the principles of ultrasonic welding, mechanized tape layering, and computer numerical control (CNC) machining operations to create three-dimensional metal parts. This article begins...
Abstract
Ultrasonic additive manufacturing (UAM) is a solid-state hybrid manufacturing technique that leverages the principles of ultrasonic welding, mechanized tape layering, and computer numerical control (CNC) machining operations to create three-dimensional metal parts. This article begins with a discussion on the process fundamentals and process parameters of UAM. It then describes metallurgical aspects in UAM. The article provides a detailed description of a wide range of mechanical characterization techniques of UAM, namely tensile testing, peel testing, and pushpin testing. The article ends with information on sensor embedding.
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005605
EISBN: 978-1-62708-174-0
... Abstract The ultrasonic additive manufacturing (UAM) process consists of building up solid metal objects by ultrasonically welding successive layers of metal tape into a three-dimensional shape with periodic machining operations to create detailed features of the resultant object. This article...
Abstract
The ultrasonic additive manufacturing (UAM) process consists of building up solid metal objects by ultrasonically welding successive layers of metal tape into a three-dimensional shape with periodic machining operations to create detailed features of the resultant object. This article provides information on the materials, welding parameters, process consumables, procedures, and applications of the UAM. It describes the methods for determining metallurgical and mechanical properties of solid metal parts to assess the range of materials and applications for which the process is suited. These methods include peel testing, push-pin testing, and microhardness/nanohardness testing. The article also reviews the issues to be addressed in maintaining UAM fabrication quality.
Image
Schematic of an ultrasonic additive manufacturing system. (a) Additive proc...
Available to PurchasePublished: 15 June 2020
Fig. 2 Schematic of an ultrasonic additive manufacturing system. (a) Additive process where the tapes are added and welded on top of each other. (b) Subtractive manufacturing where the integrated computer numerical control machining unit is used to finish the surfaces and also machine complex
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Image
Ultrasonic additive manufacturing (UAM) process. (a) UAM welding system. (b...
Available to PurchasePublished: 31 October 2011
Fig. 1 Ultrasonic additive manufacturing (UAM) process. (a) UAM welding system. (b) Machining operation
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Image
Applications of ultrasonic additive manufacturing. (a) Injection molding di...
Available to PurchasePublished: 31 October 2011
Fig. 2 Applications of ultrasonic additive manufacturing. (a) Injection molding die and part. Courtesy of Solidica Inc. (b) Plate with embedded channels. Courtesy of Edison Welding Institute. (c) X-ray of channel network in (b). Courtesy of Edison Welding Institute. (d) Embedded NiTi wire
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Image
Ultrasonic additive manufacturing (UAM) systems. (a) Solidica UAM Beta syst...
Available to PurchasePublished: 31 October 2011
Fig. 3 Ultrasonic additive manufacturing (UAM) systems. (a) Solidica UAM Beta system. (b) Solidica, Formation system. Courtesy of Solidica Inc.
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Image
The ultrasonic additive manufacturing process for producing a solid metal p...
Available to PurchasePublished: 31 October 2011
Fig. 4 The ultrasonic additive manufacturing process for producing a solid metal part. Photos 1, 3, 5, 6, and 9 courtesy of Edison Welding Institute; photos 2, 4, 7, and 8 courtesy of Solidica Inc.
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Image
Ultrasonic additive manufacturing (UAM) mechanical test specimens for shear...
Available to PurchasePublished: 31 October 2011
Fig. 7 Ultrasonic additive manufacturing (UAM) mechanical test specimens for shear (left), transverse tensile (middle), and longitudinal tensile (right) testing. Courtesy of The Ohio State University
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Image
Ultrasonic additive manufacturing mechanical testing force versus displacem...
Available to PurchasePublished: 31 October 2011
Fig. 8 Ultrasonic additive manufacturing mechanical testing force versus displacement plots for (a) transverse tensile, (b) shear, and (c) longitudinal tensile tests. Courtesy of The Ohio State University
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Image
Peel test applied to ultrasonic additive manufacturing builds. (a) Schemati...
Available to PurchasePublished: 31 October 2011
Fig. 9 Peel test applied to ultrasonic additive manufacturing builds. (a) Schematic of floating roller peel test. Source: Ref 10 . (b) Typical peel test force-displacement curve
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Image
Push-pin test applied to ultrasonic additive manufacturing. (a) Schematic o...
Available to PurchasePublished: 31 October 2011
Fig. 10 Push-pin test applied to ultrasonic additive manufacturing. (a) Schematic of push-pin test. (b) Typical push-pin test force-displacement curve. Source: Ref 22
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Published: 15 June 2020
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Images of various parts fabricated using ultrasonic additive manufacturing....
Available to PurchasePublished: 15 June 2020
Fig. 1 Images of various parts fabricated using ultrasonic additive manufacturing. (a) Heat exchanger fabricated with hybrid capabilities. (b) Component with embedded electronics. (c) Component with embedded fiber optic strain gages. (d) Heat exchanger. (e) Heat exchanger fabricated
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Bond formation in ultrasonic additive manufacturing. (a) Schematic illustra...
Available to PurchasePublished: 15 June 2020
Fig. 5 Bond formation in ultrasonic additive manufacturing. (a) Schematic illustration of head-to-head welding of gold nanowires where one nanowire is caused to approach the other. STM, scanning tunneling microscope. (b) and (c) The motion in (a) is shown in transmission electron microscopy
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Image
Ultrasonic additive manufacturing (UAM) fiber-optic-sensor-embedding proces...
Available to PurchasePublished: 15 June 2020
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(a) Schematic of the ultrasonic additive manufacturing process. (b) Typical...
Available to PurchasePublished: 15 June 2020
Fig. 2 (a) Schematic of the ultrasonic additive manufacturing process. (b) Typical microstructure of the foil interface, showing grain refinement and potential plastic flow directions. USW, ultrasonic metal welding; CNC, computer numerical control. Source: Ref 2
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Image
Applications of ultrasonic additive manufacturing. (a) Injection molding di...
Available to PurchasePublished: 15 June 2020
Fig. 3 Applications of ultrasonic additive manufacturing. (a) Injection molding die and part. Courtesy of Solidica Inc. (b) Plate with embedded channels. Courtesy of Edison Welding Institute. (c) X-ray image of channel network in (b). Courtesy of Edison Welding Institute. (d) Embedded nickel
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Book Chapter
Ultrasonic and Thermal Metal Embedding for Polymer Additive Manufacturing
Available to PurchaseSeries: ASM Handbook
Volume: 24
Publisher: ASM International
Published: 15 June 2020
DOI: 10.31399/asm.hb.v24.a0006558
EISBN: 978-1-62708-290-7
... Abstract This article provides an overview of the implementation of wire embedding with ultrasonic energy and thermal embedding for polymer additive manufacturing, discussing the applications and advantages of the technique. The mechanical and electrical performance of the embedded wires...
Abstract
This article provides an overview of the implementation of wire embedding with ultrasonic energy and thermal embedding for polymer additive manufacturing, discussing the applications and advantages of the technique. The mechanical and electrical performance of the embedded wires is compared with that of other conductive ink processes in terms of electrical conductivity and mechanical strength.
Book Chapter
Deformation Processes in Additive Manufacturing
Available to PurchaseSeries: ASM Handbook
Volume: 24
Publisher: ASM International
Published: 15 June 2020
DOI: 10.31399/asm.hb.v24.a0006572
EISBN: 978-1-62708-290-7
... and development continues in DAM processes, they are becoming increasingly attractive, especially for the AM of metals. This article discusses some of the more widely used DAM processes, namely ultrasonic additive manufacturing, cold spray process, and friction stir welding, focusing on their applications...
Abstract
The majority of currently used additive manufacturing (AM) processes are solidification based (SAM). Another class of AM processes consists of those that rely on deformation (DAM) to place material instead of solidification. Although SAM processes are much more widely used, as research and development continues in DAM processes, they are becoming increasingly attractive, especially for the AM of metals. This article discusses some of the more widely used DAM processes, namely ultrasonic additive manufacturing, cold spray process, and friction stir welding, focusing on their applications, advantages, and limitations.
Book Chapter
Additive Manufacturing of Copper and Copper Alloys
Available to PurchaseSeries: ASM Handbook
Volume: 24
Publisher: ASM International
Published: 15 June 2020
DOI: 10.31399/asm.hb.v24.a0006579
EISBN: 978-1-62708-290-7
... processes include binder jetting, ultrasonic additive manufacturing, directed-energy deposition, laser powder-bed fusion, and electron beam powder-bed fusion. The article presents a review of the literature and state of the art for copper alloy AM and features data on AM processes and industrial practices...
Abstract
This article is a detailed account of additive manufacturing (AM) processes for copper and copper alloys such as copper-chromium alloys, GRCop, oxide-dispersion-strengthened copper, copper-nickel alloys, copper-tin alloys, copper-zinc alloys, and copper-base shape memory alloys. The AM processes include binder jetting, ultrasonic additive manufacturing, directed-energy deposition, laser powder-bed fusion, and electron beam powder-bed fusion. The article presents a review of the literature and state of the art for copper alloy AM and features data on AM processes and industrial practices, copper alloys used, selected applications, material properties, and where applicable, compares these data and properties to traditionally processed materials. The data presented and the surrounding discussion focus on bulk metallurgical processing of copper components. The discussion covers the composition and performance criteria for copper alloys that have been reported for AM and discusses key differences in process-structure-property relationships compared to conventionally processed material. The article also provides information on feedstock considerations for copper powder handling.
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