Ultrasonic Additive Manufacturing: Weld Optimization for Aluminum 6061, Development of Scarf Joints for Aluminum Sheet Metal, and Joining of High Strength Metals
Ultrasonic Additive Manufacturing: Weld Optimization for Aluminum 6061, Development of Scarf Joints for Aluminum Sheet Metal, and Joining of High Strength Metals
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超声波增材制造：铝 6061 的焊接优化、铝板材斜接接头的开发以及高强度金属的连接
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发表时间：
2015
期刊：
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通讯作者：
P. Wolcott
中科院分区：
文献类型：
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作者：
P. Wolcott
超声波增材制造（UAM）是一种低温固态制造工艺，能够创建具有设计的各向异性和嵌入材料的分层固体金属结构。作为一种低温工艺，UAM能够创建包含智能材料、嵌入式传感器组件、热管理设备等的活性复合材料。这项工作的重点是UAM铝结构的改进和表征，提高超声波连接到板几何形状的能力，并使用该技术检查异种材料接头。通过试验设计确定了6061铝合金的最佳焊接工艺参数，最佳焊接工艺参数为焊接振幅32.8 μm，焊接速度200 in/min。焊接力和温度在所研究的水平内不显著。提出了一种创建大规模构建的方法，包括规定的随机堆叠序列和0.0035英寸的重叠。（0.0889 mm），以最大限度地减少空隙并最大限度地提高机械强度。利用热处理显着增加机械性能的UAM构建，在90%的散装材料。在UAM过程中施加的载荷进行了研究，以确定在该过程中引起的应力场和塑性变形。建模
Ultrasonic additive manufacturing (UAM) is a low temperature, solid-state manufacturing process that enables the creation of layered, solid metal structures with designed anisotropies and embedded materials. As a low temperature process, UAM enables the creation of active composites containing smart materials, components with embedded sensors, thermal management devices, and many others. The focus of this work is on the improvement and characterization of UAM aluminum structures, advancing the capabilities of ultrasonic joining into sheet geometries, and examination of dissimilar material joints using the technology. Optimized process parameters for Al 6061 were identified via a design of experiments study indicating a weld amplitude of 32.8 μm and a weld speed of 200 in/min as optimal. Weld force and temperature were not significant within the levels studied. A methodology of creating large scale builds is proposed, including a prescribed random stacking sequence and overlap of 0.0035 in. (0.0889 mm) for foils to minimize voids and maximize mechanical strength. Utilization of heat treatments is shown to significantly increase mechanical properties of UAM builds, within 90% of bulk material. The applied loads during the UAM process were investigated to determine the stress fields and plastic deformation induced during the process. Modeling of the