Effect of weld power and build compliance on ultrasonic consolidation
Effect of weld power and build compliance on ultrasonic consolidation
复制标题
焊接功率和构建顺应性对超声波固结的影响
DOI：
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发表时间：
2016
期刊：
影响因子：
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通讯作者：
M. Dapino
中科院分区：
文献类型：
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作者：
A. Hehr;P. Wolcott;M. Dapino
目的
超声增材制造（UAM）是一种基于超声金属焊接的制造技术。作为固态工艺，UAM制造期间的温度达到参与金属的熔化温度的一小部分。UAM部件在制造过程中可能会变得机械顺从，这会对焊工产生一致焊缝的能力产生负面影响。本研究旨在评估焊接功率对整个UAM构建过程中焊接质量的影响，并开发一种新的功率补偿方法以实现均匀的焊接质量。
设计/方法/方式
该研究利用机械推针测试作为抗分层性的度量，以及聚焦离子束和扫描电子显微镜来分析UAM部件的界面微观结构。
结果
焊接功率被发现对机械性能和微观结构产生负面影响。通过保持焊接功率恒定，UAM试样的分层能量增加了沿着与一致的晶粒结构。因此，为了确保整个UAM部件构造的恒定特性，维持焊接功率优于基于振幅控制的常规策略。
研究限制/影响
可以进行进一步的表征，以评估其他材料组合的功率控制策略，尽管这项研究强烈表明，无论焊接的金属如何，所提出的方法都应该有效。
实际影响
所提出的功率控制策略可以通过监测和控制供应给焊机的电功率来实现。因此，不需要额外的硬件，使得该方法既有用又易于实现。
独创性/价值
本研究论文首次认识到并解决了UAM中焊接功率输入的构建柔量的负面影响。这也是第一篇将测量的焊接功率与UAM部件的显微组织和机械性能相关联的论文。
Purpose
Ultrasonic additive manufacturing (UAM) is a fabrication technology based on ultrasonic metal welding. As a solid-state process, temperatures during UAM fabrication reach a fraction of the melting temperatures of the participating metals. UAM parts can become mechanically compliant during fabrication, which negatively influences the ability of the welder to produce consistent welds. This study aims to evaluate the effect of weld power on weld quality throughout a UAM build, and develop a new power-compensation approach to achieve homogeneous weld quality.
Design/methodology/approach
The study utilizes mechanical push-pin testing as a metric of delamination resistance, as well as focused ion beam and scanning electron microscopy to analyze the interface microstructure of UAM parts.
Findings
Weld power was found to negatively affect mechanical properties and microstructure. By keeping weld power constant, the delamination energy of UAM coupons was increased 22 per cent along with a consistent grain structure. As a result, to ensure constant properties throughout UAM component construction, maintaining weld power is preferable over the conventional strategy based on amplitude control.
Research limitations/implications
Further characterization could be conducted to evaluate the power control strategy on other material combinations, though this study strongly suggests that the proposed approach should work regardless of the metals being welded.
Practical implications
The proposed power control strategy can be implemented by monitoring and controlling the electrical power supplied to the welder. As such, no additional hardware is required, making the approach both useful and straightforward to implement.
Originality/value
This research paper is the first to recognize and address the negative effect of build compliance on weld power input in UAM. This is also the first paper to correlate measured weld power with the microstructure and mechanical properties of UAM parts.